Combustion Turbine Blade Assembly:  Complete assessment, design, consolidation of two buildings into one dedicated to this business. Two value steams defined and implemented. All fork lift handling eliminated between operations. One-unit flow implemented. Inventory reduction of $1.8M, capacity increase of 2.7X, Mfg cycle time reduced 88%. Scrap and reword reduction of 22%. Labor productivity increase of $2.8M.

 

Lean Implementation - Electronic Product Manufacturer:  Complete assessment, design, and implementation. Dramatic improvement in customer service, major reduction in inventory, customer lead-time reduced 56%, and rework reduced 11%.

 

High Speed Inspection Equipment Manufacturer:  Assessment, roadmap, plant layout, and implementation. Production throughput increased 2X, cycle time from 5 weeks to 5 days, and 50% inventory reduction.

 

Large Fan Producer:  Plant layout for company closing 100 year plant and building a new one to this layout design. Mapped old facility and determined new facility layout. Major improvements in flow, facility size reduced 20% including room for expansion. Fork lift traffic dramatically reduced with inline flow processes for various fan types.

 

Vinyl Products Manufacturer:  5S implemented with major improvements in people involvement, cleanliness, always tour ready, and performance metrics made visual.

 

Military Communications Provider:  Implemented Quick Changeover in high-speed circuit board manufacture. First did a prototype line and then implemented on all 6 lines. Average changeover time reduced from 98 minutes to 37 minutes, a 62% reduction. There are more than 50 changeovers per week.

 

Paper Producer: Quick changeover implemented on paper re-winder. Achieved 60% reduction in changeover time.

 

Tier 1 Automotive Electronics Supplier: Assessment. Defined processes for implementation of ISO TS16949.

 

Vinyl Extrusion Facility: Implemented quick changeover for color changes on all extrusion lines. Achieved 50% reduction in color changeover time.

 

Oil Rig Pipe Supplier: Implemented quick changeover. Implemented quick changeover on press line and threading line. On press line the good-product to good-product changeover time was reduced by 82%. On the treading line the good-product to good-product changeover time was reduce by 57%.  

 

Photonic Manufacturer: Trained and implemented SPC capability within the company to center the process and improve quality throughout.

 

5S Projects