Operational Excellence – PITSTOP

Operational Excellence – PITSTOP

PITSTOP is also known as SMED is a Focused Improvement tool that will create breakthrough results in your Profitability and Operational Excellence journey achieved through Overall Equipment Efficiency losses elimination. In addition to Lean Tools use, our consultants will investigate all Changeovers, Cleaning, and Sanitizations events/practices via various types of assessments: Time Studies, Motion studies, Ergonomics assessments, 5S audits, process parameters measurements, video recordings, employee diagnostic and skills assessments – integrated with the DMAIC methodology to reveal optimizing opportunities to:

Reduce Setup times

✔   Reduce Impact of those non added value processes to drive improvement of line Efficiencies and Capacity Utilization

   Increase Operating flexibility

✔   Gives capability for shorter runs and thus less inventory and more floor space

✔   Reduce Material Handling

✔   Increase operator capability, efficiency, and Safety.

✔   3-5 Points-% improvement on production line OEE.

✔   > 90% Line Capacity Utilization.

✔   Standard Work & Continuous Process Flow.

✔  Equipped, Engaged and Empowered Workforce.

✔  Automation Solutions and Interfaces.

Our Methodology


✔   Problem Statement : Gap to targeted OEE and utilization caused by C/O – CIP

✔   Business Impact and Benefits

✔   Team and Scope


✔   $ Value for 1 OEE Over heads /Line costs

✔   Tiime/Motion studies – capture all current process steps

✔   Identify Internal , external, non added value steps

✔   Study Process Parameters ( CIP, temp, flow rate)- (C/O fittings, equipment subcomponents)

✔   Employee Diagnostics- Skill assessments

✔   Line As -Is Audits – 5S

✔   Video recording


✔   Brainstorming , Nominal Group Technique

✔   Problem solving Techniques: FMEA, 8D, 5 whys,BDA, FISHBONE

✔   Gap Analysis- Current OEE VS Glide path

✔   Effort /Impact Matrix , SWOT


✔   Eliminate non added value steps and convert internal to external

✔   Generate ideas for 5S – Motion – Ergonomics improvements

✔   Simplify fittings and installations and optimize parameters

✔   Reduce time of adjustments and trials

✔   Standard Work Strategies

✔   Vertical Startups -VSU


✔   Create Balanced Scorecards for tracking

✔   Workforce Training

✔   Visual Controls , Centerlines -Andon , Poka-Yoke, Jidoka

✔   SOPs

✔   MES/ERP — Data Capturing

Related Case Study

Case : Chools was hired by 100 fortune Food and beverage company in MEA Region to drive and develop its Productivity, Lean Six sigma, performance and TPM journey. CIP and QCO PITSTOP was one of the methodologies used to drive OEE Improvement.

Act : Chools Consultants conducted pitstop across 8 plants – 16 production lines. Our consultants inside the DMAIC methodology used the various assessments and several Lean problem solving and analysis tools and above all trained the team.

Results : An annual Increase of 10% OEE points was realized for the region, this translated to $3.8MM – 3.7% of Manufacturing Base spend.

Savings captured encompassed all MOH ; Labor utilities , Maintenance and operating supplies costs.

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