Falcon: Smart Handmade Reporting

An essential tool for the efficient management of accurate and up-to-date key performance indicators

At Insta-Lean, all our projects begin with the creation of a "tailor-made" Visual-Reporting program.

What cannot be measured cannot be controlled; what cannot be controlled cannot be managed; what cannot be managed cannot be improved.

In an industrial environment where decision-making must be based on accurate and up-to-date data, Hawk It becomes an essential tool for the efficient management of key performance indicators (KPIsThanks to its direct access to the database and the ability to register information in situ, Halcón provides detailed real-time reports, ensuring a clear view of operational performance.

Falcon's Objectives

Facilitate the collection and analysis of operational data in real time.
Standardize the measurement of KPIs to improve comparability and control of results.
Automate report generation daily, weekly and monthly.
Identify performance trends for the continuous optimization of processes.
Reduce the time spent on administrative tasks related to KPI monitoring.
Ensure the efficient dissemination of information at the end of each shift.

How the Falcon Works

Real-time data recording and collection
- Operators can enter information directly into the platform from the work site.
- Direct connection to databases to automatically capture key metrics.
Automatic report generation
- Daily reports: Summary of KPIs for each shift, automatically distributed to the team.
- Weekly and monthly reports: analysis of trends and cumulative performance.
- Historical comparisons to identify areas for improvement.
Trend and performance analysis
- Pattern detection in production, maintenance, and operational efficiency.
- Early warnings for performance deviations.
Efficient dissemination of information
- Automatic distribution of reports at the end of each shift.
- Interactive dashboard visualization for better data interpretation

Benefits of using Halcón

Greater accuracy and reliability in KPI monitoring.
Reduction of time spent on manual reports.
Better decision-making based on up-to-date data.
Process optimization through trend detection.
Greater transparency and communication within the team.

With Hawk, Companies can transform their operational data into strategic information to improve efficiency, quality, and overall performance.

Lead Times Control

Dynamic Value Stream Mapping (DVSM) Tool

Any company working in the retail industry should be able to measure its end-to-end process times in just a couple of clicks. Gone are the days of annual Value Stream Mapping diagnostics to identify bottlenecks and potential improvements in a value chain. Lead Time Control allows you to monitor lead times across the entire chain globally, by process, month, week, and even by order!

There are no more secrets: How long does it take to register an order in the system? To prepare it? To produce it on each machine? To ship it? With this tool, you'll now know everything.

Lead Time control module: value stream mapping tool

The new Lead Time control module is an expansion of our already implemented Halcón management software.

The Lead Time control module allows us to monitor our end-to-end process times with a single click, showing how long each stage takes from the moment the order is created, entered into the system, printed, shrink-glued, die-cut, folded, and finally shipped to our customer.

To constantly measure and improve our performance, we have this control available by year, month, and week, as you can see in the image. The Halcón Lead Time control module also offers the possibility of working on a specific process or viewing an order in detail.

For example, a salesperson who is going to deliver a product that is printed, laminated, die-cut, and folded could, in this case, be perfectly sure that they could deliver it safely in twenty-one working days, because that is the average time that more than 700,000 units have passed through during this year 2018 in this company.

And we can control this for any type of process; for example, in this case, IT would be printing and die-cutting. What this tells us is that this process actually takes between one and five days.

Improved value stream

What is surprising is the potential for improvement we found in this part of the value chain, where there was no actual production. When I say no production, I mean we're not printing, we're not handling the cardboard. However, there are some production processes that, in some way, we see as having significant potential for improvement.

This is reflected in this indicator. This indicator shows the administrative process, represented in blue, from the moment the order is placed and enters the printer, comparing it to the production process at the plant, from the first printed page to shipment to the customer.

This is also very practical, being able to observe this by process, for example, the most complete one. ICT: Printing, laminating, die-cutting and folding, where we can see that in this last month we have a peak in the production part.

It can also be very interesting to see a specific order, for example, how long it took to make this box. It took 13 business days. We can see that this is quite a short time compared to the average.

In addition to being a tool for monitoring and improving the overall efficiency of the company, this Halcón module is very useful for salespeople when it comes to committing to a reliable delivery date.

As you will understand, now nothing is easier, since we have a history that is very simple to understand and very accurate.

In short, we can keep track annually, monthly, weekly, daily, and even by order, allowing us to plan safely.

Delivery time is key; often the fastest company wins the order over a slower one, and that's why it's essential to be able to control these times with a simple click!

Hawk

Kaizen/Treasures Module

Kaizen is the essence of Continuous Improvement: Creating work teams to improve a specific aspect of the plant.

Insta-Kaizen is a Reporting module that allows you to find "What" to Improve directly prioritizing the problems experienced by the operators and reported by them.