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(meat processor)
• Overcame previous resistance to "impossible"
major operating changes
• $8 million per year immediate cost savings; $22 million
potential
• $10 million near term capital investment avoidance
• Adopted new paradigms for developing operational improvements
Lean Manufacturing Line Redesign
(industrial equipment manufacturer)
• Used Lean Flow best practices
• Minimized non-value overhead
• 50% productivity increase
• 80% WIP inventory reduction
• 80% lead time reduction from 10 days to 2 days
Manufacturing Strategy Development
(hardware supplies manufacturer)
• Used Lean Flow Mfg. best practices
• Minimized non-value overhead
• Clarified requirements for a new management information
system (ERP)
• Reached a consensus understanding of how the manufacturing
and overhead functions will have to become “leaner”
to maintain market leadership
Streamlined Business Support Processes
(meat processor)
• $760,000 “hard” cost savings
• $1 million “soft” cost savings for further
development that will help avoid near term staff additions
• Created action plans to solve several chronic problems
in scheduling, customer service and other areas.
• Outlined a customized Continual Improvement Process
to meet the specific business and cultural needs.
(first-tier automotive supplier)
• 80,000# mold change times reduced from 2.5 hours to
30 minutes by the Tool Swap Team. Changeovers as fast as Indy
pit-stops.
• Eight miles of daily walking eliminated in trim cells
by the initial 5S Team
• 10,600 SF of floor space square feet liberated by
the Clean Sweep Team
• Materials handling costs saved by the Rack Readiness
Team
(electronic equipment manufacturer)
• Reduced line changeover time from 1 hour to 12 minutes
• Increased net throughput capacity by 25%
• Increased marginal income by $3.5
million per year
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