Planning and synchronization of flows

Ensure your competitiveness through the intelligent organization and digitalization of your value chain from order taking to delivery!

By properly synchronizing your processes and guiding your teams in line with customer needs, you can face the diversity imposed by the market with serenity.

What is VIP 2?

VIP2 is the digital visual management system for capacity planning and scheduling
and the synchronization of your real-time and extracted streams.

It takes into account the specifications, constraints and subtleties of the processes, zones or production equipment.

It ensures, in simplicity, the flexibility of production and its adaptability to the diversity of product types, while guaranteeing the necessary flexibility in the face of fluctuations in volume demand.

It adapts to variations in rhythm according to the circumstances and ensures the stability of production with complete serenity.

VIP2 = Valessentia Vvisual IInteractive IIntelligent PushPull

Moving from a push system
to a production just necessary

PUSH - Pushed flows

PULL FLOW - VIP2

Real demand
Resources just enough
Minimized stock, fast delivery
Synchronous use in rhythm with the takt
Production in a serene process
Increase in production capacity

Planning

Consumption triggers the action. Programming a station automatically generates a ground signal.

Synchronize

The upstream is synchronized. Each actor receives the information to produce according to the actual customer needs.

Mastering

The field remains connected with a direct connection to the machines and operators.

Stop relying on experts; take back control of the management of your value chain.

Increase in capacity, productivity and financial performance

Improve your company's performance by maximizing the volume of production, reduced stocks and a +30% increase in productivity.

Organization, digitalization and reliability of processes

Standardized, digitized processes that are controlled in real time to put an end to the firefighting mode and ensure predictable production, without dependence on experts and without loss of know-how.

Reduction and reliability of deadlines

Deliver what you promise with a service rate of over 90% thanks to times shorter and more robust flow paths.

Predictability and end-to-end visibility of your production

Avoid the occurrence of emergency situations thanks to a monthly activity level agreement between Sales, Supply Chain and Production on a fixed and smooth schedule.

Planning & synchronization of flows

Drive your business with synchronized, real-time customer-driven flows and reduce the 60%-replanning.

Mastery and control of the stops experienced

Control variability by measuring in real time equipment stops, failures, or changes in series.

Results observed in the field

Measurable performance
from the very first weeks.

Increase in productivity

+ 0 %

Maximizing the volume of products produced

Stocks & encours

- 0 %

Reduction of finished product stocks by 50% and backlog divided by 5

Reliability of deadlines

> 0 %

Reliable service rates and customer engagement

Production capacity

+ %

Increased available capacity depending on the context

Testimonials

Now we have pre-established sequences. There are maps that are sent over the line and that allow us to coordinate all the trades. We have significantly reduced the level of stock and, in addition, we meet the OTIF (On-Time In-Full) standard to ensure customer satisfaction.

Before, we had an OTIF rate of 50 %; now we have reached a rate of 90 %. The product leaves the line, is packaged and ready to be loaded onto the truck. Today we are following a balanced approach: one operator for four lines, as opposed to one operator for one line in the past.

I think Valessentia really put us on the right track and especially led us to have a holistic vision and approach our Lean transformation in a completely holistic way. Unlike in the past, where we would tackle small projects one after another. Today, the big transformation is a cultural transformation with a completely different vision, particularly this inverted pyramid approach where today we are totally focused on local support and support for the field teams.

More than just a project accompaniment, it was a change in culture. We implemented a structured and synchronized teamwork. We wanted to reduce the lead time for our new products and capitalize on our expertise so as not to repeat the same mistakes as 10 years ago. This experience changed the company and gave me a real foundation to continue to progress. The creation of the validation consensus was a real challenge: before, we sometimes validated the opposite of what had been agreed the day before! We also introduced visual management to boost decision-making. We used the standard tools to capitalize on the know-how. We achieved our lead time reductions, but beyond that, it's this culture of change which was the key to success.

Our factory in Turkey was not affected by either the pandemic or supply chain problems. I have shown this through the figures and results: She has always remained stable and calm. What Valessentia has done with us, every time, brings serenity to the teams.

Scheduling is now much more in line with customer needs than in the past, when we optimized to reduce our production costs. Production management is now done through the management by the ekekanban. This allows us to more precisely manage the customer's demand. Every morning, each operator finds a task to perform, which makes their life easier compared to the multiple Excel files of the past. With the ekanban, we perform the sequencing on a daily basis. Ultimately, this gives us the opportunity to revise these quantities or productions. We We adapt to line fluctuations thanks to the system that sends us cards during consumption, allowing us to adjust production in real time to line consumption. Everything has become much smoother and easier to use.

Global synchronization

Every resource at the right time, at the right pace, and in the right order.

VIP2 aligns machines, operators, energy and supplies to the takt time, without waiting and without overstocking.

Synchronization is the state in which each resource (machine, energy, supply) and each operator produce at the right time, at the right pace, and in the right order, without waiting or having too much stock.

Request -> production

The logistics box receives the orders (from ERP, Excel, etc.) and calculates the launch dates. The monthly contract sets the volume, mix and capacities.

Synchronization between processes

The synchronization box and the leveling box synchronize the processes contributing to the takt time, manage series changes, and absorb fluctuations in demand thanks to the supermarket.

Operators and machines

The sequencing rail guides step by step and controls the progress of the production stages and responsiveness to abnormal situations.

Our fundamentals

Customer-oriented

Reduces flow times, responds to real-time commands, eliminates the snap-back effect.

Oriented process

Synchronizing the production stages, supermarket and takt time ensure the shortest flow times.

Oriented capacity

The dashboard ensures deliverables are delivered on time and optimizes the use of each resource.

Oriented towards quality

Heijunka creates serenity: managed changes, applied standards, facilitated quality assurance.

Oriented supply chain

Timely delivery, triggered by real consumption, updated every 5 minutes.

User-oriented

Simple and user-friendly rail sequencer: every operator knows what is expected and monitors their progress, reacting to any unexpected events.

Oriented towards performance

Productivity, resource savings (equipment and energy), personnel savings, space savings, time savings, stress savings.

The customer and the Genba at the center of the game

Everyone benefits from it.

01 — Direction

Driving decisions with greater relevance

Relevance of investment choices and savings
Management alignment

02 — HR

Adapting resources to real needs

Adaptation of staffing to demand
Social peace

03 — Sales

Respond faster to market developments

Agile response to customer variations without a sudden impact
Best customer response

04 — Finance

To sustainably improve financial performance

Financial performance
Reduction of storage spaces (gain of m²)

05 — Methods / Maintenance

Structuring and sharing operational standards

Standardization of processes
Documentation of processes and know-how

06 — Supply Chain

Ensuring the flow and commitments are reliable

Reliability of deadlines
Adaptation to market volumes and mix

07 — Operational / Production

Gaining serenity and increased production capacity

Serenity of production
Increase in productivity and capacity
Traceability, predictability, visibility

"We transform complexity and diversity into elegant simplicity"

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