Providanz User Manual v 1.0

PROVIDANZ Manual Version 1.0 Jan 2014

© Copyright of PROVIDANZ . All rights reserved

1.0 Welcome to PROVIDANZ

This manul contains information on PROVIDANZ and how it should be used for best

results. Users with basic knowledge of Lean and takt – time based operations will find the it

easy to use this product . Others are adivsed to read this manual thoroughly before starting to

use .

2.0 What is PROVIDANZ ?

A browser-based video analyzer designed and developed for operations professionals ,

manufacturing engineers and process improvement consultants. It is a simple yet

powerful software that will help organizations implement Lean based process analysis and

improvements i.e., Line Balancing, 'Value-Add' Analysis, Changeover Time and Cycle

Time reduction, Kaizen identification etc.

PROVIDANZ is designed to analyze both manufacturing and service processes and is

user-friendly for both operations and engineering professionals. The diversity of applications

of PROVIDANZ ranges from simple tasks like accurate estimations of station cycle times

to complex takt-time-based assembly line designs.

3.0 The PROVIDANZ Advantage



PROVIDANZ is a high-ROI software and can be used by all operations and process

improvement professionals ( Manufacturing & Service businesses ) and also by consultants

& academicians.

Key benefits include :

Return on Investments ( RoI ) of “5x and upwards” (Refer pricing for details )

Simulate the Line balancing charts (Yamazumi) to generate multiple options on the

no. of stations required . This feature is automated with respect to the defined Takt

Time.

Identify and eliminate Non Value Adding activities in quick time

Avoid the hassle of using complex enterprise- wise softwares such as ERPs and

PLMs

Improve Kaizen hit- rates : identify and implement meaningful Kaizens in minimum

time

Generate Work Instructions ( WI ) with minimum effort .

4.0 Who should use PROVIDANZ

PROVIDANZ can be used effectively in one or many of the following situations

Manufacturing Engineering teams can analyze existing assembly lines / processes

with reference to takt times and recommend improvements for line balancing and

resource optimization.

Product Development teams to study prototype assembly activities , identify

potential bottlenecks and establish optimum no. of assembly stations required in new

line design.

Process improvement teams for Kaizen , Six Sigma projects to identify Non – Value

adding activities and kaizen opportunities

Consultants engaged in any of the above activities



High impact Lean Training for company employees and university students by

practical demonstration of Lean concepts such as Takt Time , „Value Add‟ Analysis ,

Kaizen etc.

5.0 THE PROVIDANZ WORKFLOW

PROVIDANZ follows a simple 6-step process for quick business results:

1. Capture your processes in a standard video format ( mp4 , webm)

2. Open the video on PROVIDANZ and input basic information such as Takt Time ,

Worker Utilization % etc. .

3. Play the video , breakdown the process into tasks using simple commands

4. Classify tasks as Value Adding / Value Enabling / Non- Value Adding

5. Allow PROVIDANZ to analyse your process and throw-up critical outputs such as :

Value- Add Analysis Tables and Charts

Optimum no. of stations required with regard to the takt –time – The Yamazumi chart

Kaizen Flashes

Work Instructions ( in editable MS Excel )

Kaizen Summary (in editable MS Excel )

Project Data ( in editable MS Excel)

6. Download Report, Retain or Purge Data – User has option to store / delete all related

data



6.0 How to use PROVIDANZ

PROVIDANZ follows a project approach . This means, each time a new process is required

to be analyzed , the team / individual should start by defining a New Project . The user can

establish projects and begin analyzing the process using simple menu- driven commands

described here.

6.1 LOGIN

Users need to login to start using PROVIDANZ . Only registered users are allowed to log-

in .

Registration is free for a 7 Day full feature trial . Thereafter , user needs to pay for further

usage ( refer Pricing details in Home Page ). Log- in requires users to enter registered email

and password.

LOG-IN SCREEN

If the user has forgotten the password , click on “LOGIN PROBLEM?” and enter your

registered mail ID . A new password will be sent to your registered mail id.



6.2 PROJECTS

The user will be directed to the following page upon logging in

To work on an existing project , click on “Open”

To review status of an existing project , click on “Project Info”

To delete an existing project , click on “DELETE”.

Please note , all data will be permanently removed once a Project a deleted

To start a new assignment / study , click on “ + NEW PROJECT ” . The following screen

will appear :



NEW PROJECT

Enter basic information such as Company Name , Location , Department , Project Title ,

Project Description etc. in the respective fields.

Note : Some of this information will be used to generate graph outputs and reports . Hence ,

user should enter correct information



In “ Choose Project Category” , the default category is Method Study ( refer screen

below)

In “ Choose Project Type ”, select

o “Line Design” if you wish to design a new assembly line / process . The “Number of Stations

under Study” will be 1 by default. PROVIDANZ will analyze and throw up the optimum

number of stations required with reference to the defined takt- time

o “Existing Line Analysis” if you wish to analyze an existing assembly line / process that has

multiple stations . Enter the appropriate “Number of Stations Under Study”

o “Single Station Analysis” if you wish to study / analyze a single station in an assembly line /

process . Enter 1 in “Number of Stations Under Study”

If you wish to use more than one video file for analysis of multiple trials , select “

More Than One” , else select “Only One”

Finally , after all fields have been filled- in , the “Start Project” tab will change

colour to GREEN . Click to save your NEW PROJECT and proceed to the

Analyzer Settings page

6.3 ANALYZER SETTINGS

6.3.1 For a Line Design Project , the following information needs to be keyed – in

„Value- Add‟ Analysis : Select “YES” if a “Value Add” analysis study is required

. A chart showing percentage of the tasks that are “value adding” , “non- value

adding” and “value – enabling” will be displayed during the analysis

Task Classification : Select “YES” if tasks in the process need to be classified as

“Operation” , “Transportation” , “Delay”, “ Inspection” , “Storage”. The summary

table will display categories of tasks in the process

Note : The above information will be an important source of Kaizen opportunities in

the process . Improvement Teams can focus their efforts on eliminating / reducing

non- value adding activities or redesign the process with reduced Inspection ,

Transportation , Delay , Storage activities.

Takt – Time : Select „YES‟ if there is a defined takt-time . Select “NO”



Note : Selecting „NO‟ will mean station cycle times cannot be compared to the takt-

time and will limit the effectiveness process analysis with reference to customer

requirements . The process analysis will be limited to line balancing only i.e.

comparing cycle time of various stations

Enter the defined „takt time‟ if there is one . To calculate the takt- time Or to

validate an existing takt-time , click on SHOW TAKT TIME CALCULATOR .

Refer Screen below.



Enter the Estimated Worker Utilization% . if this has already been factored – in in

the takt time estimation , enter 100% .

Enter Number of Trials as 1 , if only one trial of the process is to be analyzed .

Note : It is recommended to use more than 1 trial so as to average out any variations

during the study. Recommended no. of trials is 3

6.3.2 Follow similar steps for other Project Types i.e. Existing Line Analysis and

Single Station Analysis except that

For Existing Line Analysis , details of each station need to be entered i.e. Station

Name and Description . This information will be used to generate output graphs

and summary Data Tables. Refer Screen below .



For Single Station Analysis , enter details for the only station that is required to be

analyzed

Finally , after all fields have been filled in, the “ START ANALYZE PHASE” tab

will change to BLUE colour . Click on this to proceed to the VIDEO ANALYZER

page

6.4 VIDEO ANALYZER

This is a critical phase of the product and would require some skills . This page performs

three key functions ( for all project types ) :

1. Select Video 2. Play the video

and breakdown

process into tasks

3. Enter Task

Details



1. Select Video in the required format ( mp4, webm)

Use the Browse tab to select the video of the target process . Select the video

and click Open to open the appropriate video . Refer circled area No. 1 in the

screen below .

Note : The video MUST be in the prescribed format (only mp3, webm)

Note : For projects with multiple trials , it is advisable to open a new video

file for each trial

Note : For Existing Line Analysis study , video files of each station need to

be played / analyzed separately

2. Playing the Video and clicking the stop watch to break down the process into

distinct tasks

Once the video has been selected , click the “PLAY” & “PAUSE” tabs to

check the video . Refer circled area No. 2

Use the Speed adjustment tab to “speed up” or “speed down” the video as

required. . Refer circled area No. 2

Start the video by clicking the “Play” tab and click on the “Stop Watch”

at the end of the first task . Click again on the “Stop Watch” at the end of

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2221 1

1

12

1

1

3

1



the second task .Continue doing this till the video has played out the

target process

Note : During this process note that the “Stopwatch Clicks” tab keeps

updating the no. of clicks made . Each click indicates an identified task

element

If multiple trials are included in the same video file , use Pause for stopping

the video after the first trial , complete the data entry and then return to

analyze the subsequent trials.

Use “Pause and Redo” for getting back to beginning of the video and use

“Pause and Reselect” for seleecting another video file

Note : It is recommended this activity be carried out by a process expert /

industrial engineer who has basic understanding of Time & Motion studies and

process break down analysis.

1. Enter Task Details : Classification of each task into categories

Once the task breakdown activity is complete the “Enter Task Details” tab

changes colour to „blue”. Refer circled area No. 4 below

Click on this tab and you will be asked to enter the following details for each

task

1

4

1



Task Name

Task Description

Task Type : Select from “Operation” , “Transportation” ,“Inspection” , “Delay” ,

“Storage”

VA/NVA : Select from “Value Adding ” , “Non-Value Added” , “Value Enabling”

Note : You can click Play Task tab to play only this part of the video while entering

the task details

Click Next after entering details for each task

After entering details for each task , the “Finish Details” tab will change colour to „blue‟.

Click this tab to view a summary of the task breakdown and task details . Refer screen below.

If the information in this table is correct , click “End Data Collection” tab to proceed

to the next page i.e. Analyzer Outputs

Else, go back to Video Analyzer and redo the Video Analysis as explained earlier

(6.4)

6.5 Analyzer Outputs

Now it‟s time to look at the many outputs generated by PROVIDANZ. The outputs are a

powerful mix of graphs & data tables that will help user teams in one or more of the

following ( for all project types ) :

Identify & Implement a series of Kaizens to reduce station cycle times to match with

the defined takt- time



Simulate (play around) with the powerful and interactive Yamazumi ( Line

Balancing ) Chart and generate multiple scenarios of station designs and select the

best option with respect to resource utilization and takt- time

Identify Non Value Adding activities in the process and plan for elimination /

reduction – as a result, redesign stations and lines.

Monitor compliance to Work Instructions / SOPs with reference to ISO 9001 or

TS 16949 / TL 9000 etc.

Generate Work Instruction for each work station.

ANALYZER OUTPUTS

6.5.1 DATA TABLES

The basic output is that of data tables (refer screen above).

Switch between view of summary data and detailed data by clicking “Hide Details”

and “Show Details” . Refer area circled 1 in the screen above

A MS Excel editable format of this data can also be downloaded by clicking “Video

Analysis Data” . Refer area circled 2 in the screen above

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c

2

3



Similarly , click on the “Work Instruction Sheets” tab to view and download Work

Instruction . Refer area circled 2 in the screen above

Note : The takt time can be reset to a different values on this screen to simulate

multiple scenarios . Refer area circled 3 in the screen above.

6.5.2 CHARTS

Select “CHARTS” to view following powerful and informative charts ( refer screen

below )

Range Chart for Task Cycle Times ( for more than 1 trial)

Task Sequence Chart

Value Analysis Chart

Line Balancing Chart ( Yamazumi )

RANGE CHART

The range chart shows the minimum and maximum cycle times of each task that was

clicked during the video analysis . Abnormally high ranges in tasks will require

further investigation and possibly a Re-Do of Video Analysis .

Note : This chart is relevant for more than 1 trial.



TASK SEQUENCE CHART

The Task Sequence chart is a horizontal bar chart showing summary of the tasks and

their cycle times

Running the cursor on individual tasks will pop up details of each task



VALUE ANALYSIS CHART

The Value Analysis chart is a very important output for user teams . It is a modified

pie-chart that shows % age Value added in the process . It also displays activities that

have been categorized as Non – Value Adding and Value enabling

In the centre of the chart , is summary information for each task / category which get

displayed as the cursor is moved over each task / category

User teams can use this to further investigate and reduce / eliminate Non – Value

adding content in the process . Product Development teams can use this information

to re-design the station configuration for a more efficient assembly line



THE YAMAZUMI ( LINE BALANCING) CHART

The Yamazumi or the Line Balancing chart is the most powerful feature of PROVIDANZ.

Users can generate multiple line designs by using the 'click & move' simulation feature

provided on the Yamazumi chart. Taking task details and takt time into consideration, tasks

can be moved from one station to preceding or succeeding stations. Kaizen alerts are

automatically displayed whenever station cycle time exceeds the defined takt-time.

The default Yamazumi chart displays all stations and their cycle times . The green bubbles at

the bottom of each station indicate station utilization %ages i.e. cycle time as a percentage of

takt – time

Stations that have a cycle time greater than takt- time are process bottlenecks and

will require action .

The interactive Yamazumi provides 2 alternatives for such situations

The first alternative is to re- arrange tasks in each station to ensure some tasks

are added to stations having low utilization . In the screen shown above , the

last station has a low utilization - 31.8 % .

This means either the entire station can be removed by moving the tasks in this

station to other stations Or some tasks from other stations having cycle times

greater than takt time can be moved to this station



If you click on a task at the top of a station , it will move to the NEXT station

. If you click on a task at the bottom of the station, it will move to the

PREVIOUS station.

It is possible to re- arrange tasks by moving them to other stations till an

optimum setting is achieved i.e. a situation where all stations have cycle times

lesser than the defined takt times .

Note : The takt time itself can be changed to observe the impact on station

configuration

Click “Reset Line Design” tab to go back to default setting . Click “Save

Line Design” to save final setting. Refer revised Yamazumi shown below

Even , the optimum condition may have a few stations with higher cycle times (refer

screen above )

The second alternative is to reduce cycle time of the specific stations through Kaizen

identification and implementation .

ADDING KAIZEN IDEAS

For each such station , the Yamazumi will display a Kaizen Flash ( refer

yellow callouts in screen above)



It is possible to reduce station cycle times by identifying & implementing

Kaizens. Click on the Kaizen callouts and add Kaizen ideas ( as many as

identified ) . Type each Kaizen idea in the box provided and click “Add

Kaizen Idea” . Refer screen above .

Click “Close List” after all ideas have been added.

Repeat this for each station showing a Kaizen flash .

Click on the Kaizen Table tab at the bottom of the page to view a summary

table . Add implementation plans and other details . Use this table for future

reviews and monitoring

Note : If both the above alternatives fail to provide a solution , the team has to

consider adding extra stations to ensure stations cycle times are below takt-

times.

Documents

Providanz User Manual v 1.0