Looking for a Throughput Improvement Project that Goes from Start to Finish AND Pays for Itself in Less than a Year? Look no Further.

Jan 13, 2021

Manufacturing companies frequently embark on improvement projects that drag on longer than anticipated, draining resources and causing disruption to current processes over an extended period of time. Despite careful planning, these projects can still end with less than favourable results that aren’t sustainable over the long term.

Are you looking for a proven strategy with lasting results that requires minimal investment of time and energy and won’t turn your current processes and systems upside down? You can tick all of those checkboxes and more with Phenix Planning and Scheduling. Using advanced algorithms this software solution uses the concepts of Product Wheel Scheduling, a method focused on a regularly repeating sequence of everything you need to produce. Production is optimized to simplify changeovers, increase throughput, and reduce loss.

This approach brings significant value to companies – fast. Companies experience visible payoffs less than a year from the start of the project. And with a solid software solution, the benefits of using a Product Wheel approach are easy to see and maintain over time. Here are three key reasons why Phenix results in immediate value, making it an ideal throughput improvement project.

1. Rapid Implementation

One of the many benefits to Product Wheel improvement projects using Phenix is the ability for rapid, holistic execution. Using proven processes that incorporate a short, well proven roadmap, the software enables Product Wheels to be implemented within 4-6 weeks. The speed and effectiveness of implementation means you’ll start to see lasting improvements in short order. Having a well controlled project timeline reduces the likelihood of having to manage changes in production line-up, environment, or forecast change before implementation is finalized. Once Phenix is up and running, these changes are easily incorporated into scheduling – you’ll experience smooth sailing and be equipped with the tools to easily manage any waves that come your way.

2. Leverage What You Already Have

Rather than turn your world completely upside down, Phenix works to leverage your existing resources by building capacity and resource capability in four main areas:

Phenix automates all of the routine “busy work”, empowering key players to switch from “fire-fighting” mode to having the capacity to deal with unexpected events and focus more on making business decisions. It provides a framework to capture scheduling best practices and business rules. This makes it easier to train team members, resulting in more seamless transitions when key people go on holiday or move to a different role.

Rather than continuing to run overtime or investing in new equipment to meet customer demand, Phenix will use Product Wheel methodology to uncover capacity you didn’t realize you had on your existing lines. As production settles into a regular, more predicable pattern, you may find that some production lines don’t have to run nearly as many shifts.

Phenix can be readily integrated with your existing ERP or planning systems. It has flexible import mapping with extensive error checking. It’s important to us that Phenix complements what’s already in place. Rather than reinvent the wheel, we coordinate all of the pieces for smoother, faster travels to the destination.

Manufacturing Technology. Phenix is built on a set of proven industrial engineering technologies, organized into an integrated methodology called Product Wheel scheduling. A number of companies including DuPont, Dow Chemoical, Exxon Mobil and AstraZeneca have employed wheels to significant operating advantage. Our team members are globally recognized as leaders in the application of these concepts, and have even authored books on it!

3. Built in Sustainability

You have probably had experiences where you engage in a throughput improvement project, the implementation appears to be successful, but then things start to fall by the wayside. We’ve all seen it. To ensure this frustrating outcome doesn’t happen, the Phenix implementation process anticipates speed bumps and roadblocks, and builds in effective countermeasures. The tool was developed with the goal of being easy to use and maintain. Extensive hands-on training is provided during implementation, with training materials made available on a self-serve basis afterwards to refresh skills or for easy onboarding of team members. Throughout implementation, we ensure new users gain the skills and confidence required to successfully design, schedule, and maintain efficient production lines using Phenix. And our team will stay in touch to share new feature releases and provide ongoing technical and bug fix support.

If you’re looking for an effective throughput improvement project that will demonstrate quick results and pays for itself in less than a year, Phenix Planning and Scheduling is the way to go. These projects can go from start to finish rapidly, leverage your existing resources and capabilities, and ensure the value you see during and immediately following the implementation will be maintained over time. Your newly discovered throughput improvement won’t be going anywhere.

Contact us to learn more about how implementation of Product Wheels with Phenix Planning and Scheduling can make a lasting impact on your company. 

About the Authors:

Peter L. King, CSCP, is a principal consultant at Zinata Inc. specializing in the application of lean concepts to process manufacturing and global supply chains. He previously spent 42 years at DuPont where he transformed manufacturing operations and global supply chains through Value Stream Mapping, Supply Chain Mapping, inventory optimization, and other Lean tools. King is the author of several books including The Product Wheel Handbook. King may be contacted at peter.king@zinata.com.

Alan H. Nall is the Head of Customer Success for Phenix and a principal consultant with Zinata Inc. specializing in manufacturing improvement and program and project management.  Prior to Phenix and Zinata Inc, he spent 32 years working for and with companies like P&G, DuPont, Eli Lilly & Co., Pioneer Hi-Bred, MillerCoors and NB, consistently identifying and executing change that improved results, saved money and built capability. Nall may be contacted at alan.nall@zinata.com.