Gemba Solutions allows customers to understand the what, where, how, who and why of their production facility helping them to improve customer satisfaction, increase production, reduce waste, use less energy and reduce cost

1. Gemba Solutions
Introduction

2. 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.

3.  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

4. Gemba Solutions
What 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

5. Our Customers

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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
Logger
Data Server
Logger
Windows
workstations

12. Shop Floor Process Management
User-configurable shop-floor overviews provide a simple mechanism
through which the shop-floor team can select products, enter stoppage
reasons and view current status

13. Process Event Viewer

15. Target Boards

16. Shop Floor Area Overview

17. Shop Floor Line Overview

18. 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

19. Shop Floor Performance Board

20. Visual Management OEE Reports

21. Pareto Analysis

22. Comparison Analysis

23. Core Module
- Efficiency
Tracking
Labour
Document
Submission
Gain
Services
Sequencing
Andon
Alert Process
Maintenance
Q/A
Shopfloor
Visualisation
Production Toolkit

24. 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