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4 Wall Production System (4WPS)

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How We Make It Happen

Quality is first associated with products in manufacturing. But products are made by following an intricate formula of processes that are further supported by sub-processes—and so on and so on. Quality in these processes is what really drives great results! We make this easier to achieve and sustainable by utilizing a 4-phase approach that addresses the fact that change is hard and must be addressed consistently in order to get buy-in from the floor, functional teams, and leadership.  Applying change management in a practical and non-threatening manner is our secret sauce: Easy to say … hard to do! Here is our approach:

Phase 1

Gain Control & Set Daily Expectations

Win the hearts and minds through engagement of people, containment of problems and organizational alignment through the use of SQDC boards.
woman in factory facility
engineers meeting

Phase 2

Manage Daily Improvement (MDI)

Tasks are tracked and delivered in discrete and time bound buckets. Every day “wins” become the norm and missed targets become endangered as teams work together to achieve “tough” progress.

Phase 3

Launch Leader Standard Work

Full alignment of the cross-functional management team provides a transparency that rapidly turns cultural blemishes into opportunities to fully leverage the LEAN manufacturing tools that fit your operations.
floor meeting
production status board

Phase 4

Achieve Autonomous Operations

The entire organization is focused, motivated, and develops a proactive, “We got this” toughness when tackling challenges that had prevented continuous improvement initiatives from taking root.

Safety

It’s everybody’s most important thing

Going home to see your friends and family after a good day of work is a just reward, and ensuring your culture is both healthy and engaging improves all other aspects of your business.

Quality

Know what your customer is getting

Ensuring everyone knows what the customer got, or did not get, is at the heart of Quality programs. Having processes and safeguards in place to prevent unwanted surprises is essential.

Delivery

Know when your customer is getting it

A car or truck may have 100,000 parts coming from 1,000 suppliers. Knowing that your parts got to their destination on time, in sequence via the correct mode of travel provides both confidence and the ability to focus on core functions.

Cost

Cost attainment is not a national secret

Transparency in cost metrics throughout the supply chain offers areas to improve, as well as an early warning to the business leadership. Ensuring each worker has an understanding of their role in cost attainment empowers supervisors and managers.

Ready to Transform Your Operations?

Make FireFighting a Distant Memory With 4WPS

4 Wall Production System (4WPS) works for all manufacturing processes and can be applied to service, warehouse, and retail operations. Gain control of your daily workflow and empower your organization with transparent and focused tasks that make sense, not only to management, but the entire team. Data flows from the floor, through functional roles and gets reviewed daily in a cross-functional, fact-based method. This re-energizes people as they regain control, and develops a sustainable, winning culture!

Quality Drives Success!

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