Vortex Technology

Vortex is a software embodiment of the patent-pending technology developed for high-mix, non-repetitive manufacturers as an outgrowth of the DeHart Consulting LLC Lean Manufacturing methodologies.  Using the ground-breaking technology embedded in this Lean Shop Floor Control System as an add-on to an existing ERP system, expect 2 - 10x improvements in WIP and cycle time. In addition, because the Vortex demand-pull manufacturing system is completely algorithm-based, it also supports a machine learning system that will further improve your results over time.  With the advent on the Industrial Internet of Things (IIoT) and Industry 4.0, forward thinking companies are increasingly digitizing their production execution systems.  Vortex provides that opportunity to the high-mix manufacturer.

Our goal is to bring the same revolutionary improvements that the Kanban demand-pull system brought to the automotive, and other repetitive, manufacturing industry into the reach of producers with more complex workflows. Until now, demand-pull production, one of the key tenets of Lean Manufacturing, was inaccessible to non-repetitive discrete product manufacturers and semiconductor fabrication facilities because Kanbans just don't work well in this environment and the available shop floor control systems had no features available to support a pull system.  But the Vortex demand-pull manufacturing system changes all that by pulling work within the factory based on flow time instead of unit-replenishment.  Please take a look at the video below and then call or contact us for a discussion, demo, and/or an integration proposal.

Vortex Lean Shop Floor Control System - View Text of Video

Examples of the Vortex Authorization Process

    The examples set forth in the table below illustrate the WO authorization process resulting from the pull-test in different circumstances.  In all the examples, a set of WCs such as shown in the following Figure is used.  There are two WCs (WC 130 and WC 135) that feed into a third WC (WC 145) and the downstream WC (WC 145) is presumed to be healthy (reference the discussion of Work Center Performance Testing) so that the pull-testing for this WC is active. 

Read more: Examples of the Vortex Authorization Process

Demand-Based Production from a Work-Volume Perspective

When looking at authorizing work in upstream stages of production, the traditional Kanban system establishes quantity buffers, or queues, at each WC. Then when the buffer quantity hits a minimum value (the Queue Policy), the Kanban card is returned to its originating WC for replenishment. 

Read more: Demand-Based Production from a Work-Volume Perspective

Table of Definitions

The following is a Table of Definitions for the articles describing the Vortex technology.

Read more: Table of Definitions

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Engagements

Harmonic Inc

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Sunnyvale, CA, Module One
Contracted to the Vice President of Operations with the objective of expanding the electronic manufacturing operations to accommodate a 3X increase in production capacity. Formed design teams from the production, warehousing, and engineering personnel. Designed and implemented four product-focused manufacturing cells and a new stockroom and warehouse space. Worked with the architectural firm to layout, detail, and subsequently construct the expansion. 

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