GSA #:   GS-10F-0306V
DUNS #:   034239942
Cage Code:   58SR1
 
Corporate:   877-496-8811
Sales: 214-533-8571
Case Studies
Standard Site Project

Project Development of a Standard Site Lean Management System Configuration In Support of Major Logistics Company’s Corporate Objective for Standardization and full implementation of lean methodologies at all its sites worldwide.
Objectives The objective of this engagement was to assist a major client in developing a method for bringing about the establishment of standardized lean processes at all of their more than 90 existing sites as well as new sites being developed as the business continues to grow.
Unique Issues Unique to our previous experience with this client, we needed to consult with and integrate with the company’s Lean Implementation team for developing a standardized site scheme that was both compliant Lean practice and standards being promoted and implemented within the corporation and also with ISO 9001.
Results Developed & implemented the Lean Standard Site Management System for the Standard Site and the Pilot Site. Five major processes were defined for the Standard Site Value Stream Map and 262 procedures/documents developed along with installation and training of all employees at the Pilot Site. This activity was accomplished over a six months time frame. In addition the Value Stream Map for the Pilot Site was developed and the documents for that site developed from the standard site documents. Insight 1’s OneWindow® was modified to become the corporations overall document control system hosted at the client’s corporate offices. These standard site activities:
  • Dramatically reduced the time and labor required for establishing a new fully operational site with a fully documented set of processes governing its operation. (Just assumed responsibility for a worldwide logistics network spanning the USA, Europe and Asia in less than 90 days with the help of Insight 1, Inc.
  • Assured that all future sites met the corporate goal for standardized operational practices.
  • Provided a standard tool set for conversion of existing sites to a Standard Lean Practices environment yielding improved throughput, lower error rates and lowered cost. (This has been accomplished in number of sites since)

We were asked to support this effort because of our unique knowledge of ISO 9001 compliant management systems development and our prior knowledge of numerous existing sites within the client’s organization. We also were in a position to adapt our OneWindow® system to meet the requirements for a new configuration in providing a Lean Practices Value Stream Map as the top view of the document access and storage system.
Description of Services Insight 1, Inc. was engaged to apply its prior experience with this company for development of a “Standard Warehouse Site” consisting of all of the processes and process documentation necessary for quickly implementing a new warehouse site that is standardized in look, feel, processes and documentation content. This same standard site configuration is also planned for transforming all existing sites to this set of standardized processes and operations. The standard set of processes is also compliant with ISO 9001:2008 and will support quick registration of each new site or each existing site as requested by their clients. This Standard Site Configuration was developed and placed on the network as a “meta” set of documents that can be downloaded, configured and implemented as a new operational site.

The primary tasks included:
  • We assisted the Lean Implementation team of the corporation in developing a new documentation scheme for the standard site that integrates with The Client’s Lean Practices implementation objectives.
  • We developed a new Microsoft Visio Template for documenting Standard Operating Procedures in a Flow chart format.
  • We developed a Microsoft PowerPoint based template for documenting Detail Work Instructions keyed to the corresponding Sop and incorporating photos, document examples, and other visual representations into the document t6hat are keyed to detail instructions.
  • We adapted our OneWindow® document storage and access system to provide a graphic of a standa5d site top level Value Stream Map. This system was placed on the worldwide network to become the common point for storage and access of all site documentation for any site implemented utilizing the standard site materials.
  • Insight 1, Inc. collaborated with the Lean Team at the Client to develop all of the Standard Site SOPs and also reviewed and maintained the corresponding Work Instruction Documents for each SOP.
  • Insight 1, Inc. developed a standard document numbering system designed to provide organization and categorization of all documents for future sites.
  • Assisted the client in validating and updating the standard document set at a live warehouse site located near Nashville, Tennessee.
Methodologies Insight 1, Inc. utilized its knowledge and experience gained in implementing standard processes and procedures at 15 of the Client’s operational sites in support of their gaining successful registration to the ISO 9001 standard.