SIMON: Lean Transformation Process

With over a hundred years of history since its founding in Olot (Girona), SIMON has established itself as a leading name in the manufacture of switches, electrical accessories and smart lighting systems for all kinds of environments. In 2016 the company committed to a Lean strategy and, as a result, in 2018 it launched an ambitious programme at its Olot plant to transform its operations in collaboration with ASENTA, moving towards a more agile, efficient and flexible model.

The company’s starting point was the need to:

• • Reduce delivery times to customers
• • Improve material flow on the shop floor
• • Reduce factory stock at every level
• • Improve machine performance
• • Engage people through cultural change

To this end, a transformation programme was designed around the Lean strategy, aligned with the specific characteristics of the business, with strong involvement from the people at the Olot plant and the unconditional support of the Group.

The solution implemented was based on advanced Lean methodologies:

1. Macro layout to create flow and reduce lead time
2. Micro layout, with one-piece flow to ensure smooth production processes
3. Improved internal logistics, enabling greater synchronisation between areas
4. A new planning model, introducing Heijunka boards and Kanban cards
5. Standardisation at every level, including the implementation of 5S
6. Improved machine maintenance through the TPM model.
7. Development of autonomy through the implementation of UAPs.

The transformation process has enabled SIMON to radically improve both its plant layout and its operational results, consolidate a culture of continuous improvement and be better equipped to meet the sector’s future challenges. Today it is a benchmark case for its ability to combine experience, knowledge, methodology and innovation.