Gemba SolutionsIntroduction

Gemba Solutions

Proven track record in “Production Efficiency Solutions” since 1996

Combined experience of over 200 years in automation, systems

development, integration, lean manufacturing & process improvement

Sector experience includes: food & drink, automotive, pharmaceutical,

chemical & fmcg

UK based, centrally located in the midlands with global reach

Who are we…..

We are different because of the Gemba Way……

We are fanatical about making sure our customers get the benefit they’re

looking for. Of course our software provides every tool necessary to run an

efficient operation but the real difference is in our service, we help drive the

benefit into our customers business rather than just laying software on top of it.

A Proper Job - we are capable, straight and effective at what we do

We are responsible for our work and continuous improvement is a given. As

individuals and as a company we strive to be reliable, to do the right thing, and to build

our reputation by living up to the spirit of our commitments

Customer Focus - our success is based on the success of our customers

Everything we do is designed to give our customers the right tools, at the right time, at

the right price

Succeed for Each Other - we’re a community with a purpose

Our team is built on the kind of hard work, commitment and sacrifice that only comes

from mutual respect and the belief that we can do more together than we can apart.

Enduring Financial Success - as a business we expect to make a profit

Our stability and our impact are dependent on generating the income that funds our

dreams

Our Values

Gemba SolutionsWhat is our purpose……..

“To improve workplace processes through technology”

What solutions do we offer…….

OEE IMPACT

Our Windows-based solution gathers data in real-time from the plant and from the

production staff and presents that data back to the users as a comprehensive set of

reports, displays and analyses

What services do we offer…………

Gain4 Services

A comprehensive set of engineering, training and continuous improvement services

ensure that you get the very best from our products

Our Customers

We provide...

Software and services that increase production efficiency

These give you…….

Total visibility of the what, where, when and why of your facility. In other words, we

provide the tools to put you in total control of production, enabling you to be much more

proactive about driving efficiency and allowing you to make informed decisions based on

facts and data. Our experienced Continuous Improvement team can help you to make

the best use of the solutions we provide, ensuring you get maximum benefit from your

investment.

Our Proposition

A network of servers, PCs and PLCs provide a reliable backbone on which

the system can run

Step1: Plant identification

Key Point: The plant items to be monitored ( we call these assets ) from which key

manufacturing data is to be automatically gathered

Enabling OEE Data Collection

A network of servers, PCs and PLCs provide a reliable backbone on which the

system can run

Step 2: Plant Connection

Key Point: A suitable method of plant connection is identified and implemented.

Where existing plant automation and connection to that is possible a direct link is

made.

Where no suitable automation exist data collection terminals will be installed through

which data can be collected

Data Collection

A network of servers, PCs and PLCs provide a reliable backbone on which the

system can run

Step 3: Data Logging

Key Point: Data collection is linked back to a centrally located data logger this

interrogates and gathers data from the automation in preparation for transmission.

Data Collection Logging

Data

Collection

Terminal

(PLC)

Data

Collection

Terminal

(PLC)

Existing

Automation

Data Logger

A network of servers, PCs and PLCs provide a reliable backbone on which the

system can run

Step 3: Data Storage

Key Point: Data collection is linked back to a centrally located data logger via shop floor

network or corporate network, this interrogates and gathers data from the automation in

preparation for transmission.

Data Storage

Data

Collection

Terminal

(PLC)

Data

Collection

Terminal

(PLC)

Existing

Automation

Data Impact

Logger

Data Server

Logger

Transmission

A network of servers, PCs and PLCs provide a reliable backbone on which the

system can run

Step 4: Access

Key Point: Windows workstations are deployed on the shop floor and in the office areas

through which the gathered data can be viewed and analysed

Data Access

Data

Collection

Terminal

(PLC)

Data

Collection

Terminal

(PLC)

Existing

Automation

Data Impact

LoggerData Server

Logger

Windows

workstations

Shop Floor Process ManagementUser-configurable shop-floor overviews provide a simple mechanism

through which the shop-floor team can select products, enter stoppage

reasons and view current status

Process Event Viewer

Target Boards

Shop Floor Area Overview

Shop Floor Line Overview

Visual Management and Control

Optional large screens installed throughout the manufacturing area keep

the shop-floor team informed on current performance and achievement

against target

Shop Floor Management Systems

Shop Floor Performance Board

Visual Management OEE Reports

Pareto Analysis

Comparison Analysis

Core Module - Efficiency

Tracking

Labour

Document Submission

Gain Services

Sequencing

Andon

Alert Process

Maintenance

Q/A

ShopfloorVisualisation

Production Toolkit

What our Customers say……

"The product is amazing. It has changed our culture enormously on the

shop-floor and we have full visibility of opportunities. Gemba have

people who know OEE and all the difficulties in ensuring the metric is

right for you.“ Lee Riley, PPG

The software makes it easy to spot problem areas quickly, and it offers

huge value in ensuring that key decisions are taken based on factual

data.” John Joyce, Gripple

"Since we have worked with Gemba I have found their working

knowledge of lean and improvement activities enable us to harness tools

and techniques outside of our normal working parameters to improve our

business. This completes the Gemba model into a world class product

and service." Tom Spragg, Barfoots of Botley

“We almost doubled our OEE in the first 6 weeks, and as a result have

almost doubled our output on those assets. I am very happy with the

system.” John van der Voorn, Walraven BV