Case Studies

Actions

• Developed inventory management system utilizing FIFO, accounting for production reates and material lead times
• Developed production scheduling system utilzing lean principals (efficient scheduling with pull system and kanbans)
• Established employee training program for lean/six sigma principals to sustain and continuously improve existing systems
• Designed inspection tools checking part component alignment
• Designed custom tools for more efficient manufacturing operations

Results

• Eliminated all $1.5m in delinquent orders
• Eliminated all overtime
• Increased inventory turnover
• Increased first pass yield
• Decreased scrap by 65%
• Increased margin by 25%
• Significantly improved customer relationship

Actions

• Team Building and Facilitation
• Creation of Design Improvements Teams
• Revamp Production Line set up and approach
• Concept Training - Lean, Waste Elimination, Theory of Constraints, Six Sigma
• Implemented 6S
• Implemented Single Piece Flow
• Instituted inventory control
• Rapid implementation and Success Evaluation

Results

• 10% Net Profit ($2m) annual and sustainable
• Significant gross margin improvements
• Eliminated supply chain issues
• Significant safety record improvements
• Creation of data driven and improvement culture
• Significant decrease of takt time of body line production
• Project ROI used to measure all project success