Client Success: Process Improvement

Action Floor Systems Begins Lean Journey

Services: Lean Certification Training, 5S Events, Value Stream MappingELC Storage 4

Results:

  • Increased productivity by 50%
  • Increased floor space by 750 sq. ft.
  • Reduced transportation and storage time
  • Saved $7800/year in labor costs
  • Created a more flexible work area

Read the full story...


AMRON, LLC

Services: 5S Visual SystemsAMRON photo

Results:

  • Significantly improved general housekeeping throughout the entire plant
  • Increased efficiencies with gage tables and work benches
  • $100,000 in savings associated with worker's compensation YTD due to increased safety
  • Increased employee involvement

Read the full story...


Anderson Corporation

Services: Six Kaizen EventsMariaSwansonNathanRoss

Results:

  • Reduced 200 Series line size by 42%
  • Reduced packing block travel distance by 71%
  • Reduced carton pick time by 24%
  • Increased accuracy of carton pick by 50%
  • Reduced part presentation cart floor space from 146 sq. ft. to 100 sq. ft.
  • Developed staffing plan playbook to handle fluctuations in demand
  • Reduced number of decisions for picking carton types
  • Reduced line side inventory from 20 parts to zero parts
  • Set up FIFO for part presentation carts

Read the full story...


Ashland Industries

Services: Lean Certification Training, Lean Accounting, Strategic PlanningAshland Photo

Results:

  • Increased usable floor space by 6,000 sq. ft.
  • Increased weekly production from 4 scrapers to 5 scrapers without adding staff
  • Sales increased from $1.2 million to $10 million
  • Increased pride and ownership of work areas
  • Increased employee comfort level in discussing production bottlenecks

Read the full story...


Atlas Resin Proppants Believes Good People are Key

AtlasResin Services: Lean Training, Facilitation of Improvement Teams

Results:

  • Achieved a waste reduction of 2%
  • 60 new employees trained to understand Lean and Continuous Improvement
  • Reduced mixer cleaning time by 40 minutes per cleaning

Read the full story...


Barko Hydraulics, Inc.

Services: Implement Flow Manufacturing with a Pull Kanban System for Inventory

Results:

  • Lead time reduced by 50%
  • Stock outs reduced dramatically
  • Product line sales increased 5%
  • Significant reduction in assembly labor time
  • High improvement in product quality

Read the full story...


Becker Communications

Services: Principles of Lean Workshop, Value Stream Mapping, 5S, Design and ImplementationBecker Company Picture 3

Results:

  • Sales increased by $2,000,000
  • Labor costs reduced by $250,000
  • Inventory reduced by $100,000
  • Lead time reduced by 12 days
  • Other costs reduced by $10,000

Read the full story...


Birchwood Lumber and Veneer

Services: Value Stream MappingPicture 1 001

Results:

  • Sales increased more than 40% (only 10-15% would have been possible without the project)
  • Lead time was reduced by more than 50%
  • Inventory costs were significantly reduced
  • Productivity increased significantly
  • Equipment costs reduced
  • Flexibility increased
  • Value Stream Mapping is used to make additional improvements in the plant and to design a new facility layout in a neighboring city

Read the full story...


Cardinal Glass Sees Lean Rewards Clearly

Services: Lean Certification Training, Lean Workshops, Value Stream Mapping, 5S, Total Productive MaintenanceCardinal Glass Amery 2-2008 004

Results:

  • Increased square footage of stock output by 34%
  • Reduced WIP at all resources by over 50%
  • Increased accuracy in production scheduling
  • Reduced days of raw glass inventory by 66%
  • Reduced days of interlayer inventory by 63%
  • Successful doubling of sales in 2005-2006
  • Realized $215,000 in cost savings
  • Reduced wait time for packing/inspection process from 17 hours to 4 hours
  • Established new Lean Performance Metrics
  • Stock through-put increases required no capital expenditures

Read the full story...


Chippewa River Industries

000_0095Services: Principles of Lean, Value Stream Mapping

Results:

  • Cycle time in the greeting card line was reduced from 2.2 hours to 7 minutes
  • Reduced floor space of greeting card line by 40%
  • Approach is being applied to six other production areas

Read the full story...


Columbia Forest Products

Services: Lean 101, Value Stream Mapping, 5S ImplementationColumbia Photo

Results:

  • Created a more orderly work environment
  • Increased productivity
  • Gained employee enthusiasm
  • Reduced inventory by 5%
  • Raised employee satisfaction levels
  • Increased cash flow
  • Retained 5 full-time employees
  • Invested over $50,000 in employee training

Read the full story...


Custom Urethane Improves Productivity and Profit

Services: Kanban System Implementation

Results:

  • Reduction in unit labor costs generated savings of $104,000
  • Inventory reduced by $15,000
  • Lead time was reduced by 6 days
  • Material costs were reduced by $5,000 per yer as a result of making more efficient use of the curing ovens
  • Floor space requirements were reduced by 3000 sq. ft.
  • Employees became more open to change as they observed the benefits of the project
  • Company moved from losing money to making a profit

Read the full story...


Decorator Industries

Services: Value Stream Mapping and Implementation, Current State Mapping -- Future State MappingCopy of DI_roomview

Results:

  • Reduced lead time 64% from 4 weeks to 2.5 weeks
  • Reduced cycle time by 99% from 3 days to 11 minutes
  • Increased sales by 3% in 2006; 37% growth in 4 years
  • Reduced cutting-to-shipping time 76% from 8 days to 2 days
  • Increased market share

Read the full story...


Dental Crafters

Services: Lean with Legos, Value Stream MappingHPIM0318

Results:

  • Reduced remakes by 42% (saved $30,000 in 5 months)
  • Reduced quality calls by 87%
  • Reduced turnaround time by 33%
  • Increased ease of prioritizing and scheduling cases
  • Reduced work-in-process from 470 to 160 cases
  • Reduced overtime hours (saved $20,000 in 12 months)
  • Improved employee morale
  • Reinforced hiring of an Operations Manager

Read the full story...


Donaldson

Services: Principles of Lean Seminars (6), Value Stream Map, Flow Manufacturing ImplementationDonaldson Picture 4

Results:

  • Reduced lead time from 40 days to 6 days
  • Reduced material costs by $70,000
  • Reduced inventory by $100,000
  • Part travel through the factory for the selected product was significantly reduced
  • Received big boost in employee morale

Read the full story...


Durex Products, Inc.

Services: Lean 101, Quick Changeover, 5S Eventsshear2after2

Results:

  • Increased on-time shipments from 89% to 92%
  • Increased production floor space by 460 sq. ft. (1.5%)
  • Reduced non-value-added steps (walking) by 13,126 ft/week
  • Eliminated 536 forklift movements by adding lift table
  • Sold 30,000 lbs. of scrap metal from unneeded rack that was disassembled 
  • 0.3 sq. ft./hour improvement in crimping department

Read the full story...


Empire Bucket, Inc. Begins Lean Journey

Services: 2 Principles of Lean Workshops, 5S Workplace OrganizationAfter5S

Projected Results:

  • Increase annual sales by $520,000
  • Add 4 new jobs
  • Retain $300,000 in sales
  • Cost savings of $150,000 in labor, $40,000 in materials, $4,000 in Energy

Read the full story...


Federal Foam Technologies

Services: Principles of Lean, Value Stream Mapping, Cellular Flow Implementationfederal foam 1

Results:

  • Increased sales
  • Significant decrease in labor required
  • Inventory reduced by $48,000
  • Lead time was reduced by 47%
  • Required floor space reduced by 1000 sq. ft.
  • Essentially reduced expediting costs to $0

Read the full story...


Field Logic Hunts Lean Success

Services: Principles of Lean Manufacturing, 5S, Value Stream Mapping, E!WW, A3 Problem Solving, Total Productive Maintenance, SimulationDeerTargetForms

Results:

  • Increased production in Block® Target division by 20%
  • Improved Hurricane™ Target layout by 30%
  • Require increased quality from supply chain vendors
  • Experienced cost savings of $65,000
  • Increased investments by $28,500
  • Use specialized recycled materials to fill bag targets

Read the full story...


FM Enterprises

FMServices: Value Stream Mapping, 5S Visual Workplace Organization, Capacity Analysis, Plant Layout

Results:

  • Reduced overall customer lead time by 40%, even more for change orders
  • Lowered manufacturing costs by 50% for one product line
  • Reduced stress with better organization and workflow

Read the full story...


Frontier Builders

Services: Lean Manufacturing, Plant Layout, Strategic Planning, 5S, Value Stream Mapping, Standard Work Proceduresfrontier photo

Results:

  • Through-put time reduced for each home by 35%
  • Productivity improved by 15%, resulting in 15% increased sales
  • Improved predictability of delivery schedules
  • Employee involvement in improvements increased to 100%
  • Improved quality
  • Gainsharing plan put in place utilizing new measures
  • Investments to increase competitiveness to exceed $100,000
  • Two additional jobs were created, and 14 more secured

Read the full story...


Genesis Equipment

Services: Lean 101, Value Stream Mapping, 5S Implementation, Cellular FlowStout Success 002

Results:

  • Reduced lead time by >39%
  • Reduced cycle time by >42% of processing time
  • Improved profits
  • Increased cash flow
  • Increased market share

Read the full story...


The Green Bakery

ServicesGreenBakeryPhotoLT

Results:

  • Creation of 4 jobs
  • Plan to add more jobs in next 12 months
  • Projected annual sales increase of $50,000
  • Cost savings of $20,500

Read the full story...


Handishop Industries Keeps Tools Handy

Services: Lean Manufacturing, 5S, Value Stream MappingModifiedWorkstation

Results:

  • Increased client productivity by 20%
  • Increased throughput 30 to 50%
  • Cost savings of $4,000 in labor and materials
  • Increased production floor space by 25%
  • Improved employee and client morale
  • Cost savings of $15,000 in energy, overhead, and other areas

Read the full story...


Huebsch

Services: Cellular Plant Layout with Flow SeminarsHuebsch Picture 2

Results:

  • 2 day process reduced by 50%
  • Reduced loading time 1.5 hours per truck per day
  • Increased from 71 pieces to 83 pieces per hour
  • Reduced number of processing steps
  • Increased value added activity

Read the full story...


J&D Tube Benders Bent on Lean Success

Services: Principles of Lean, Value Stream Mapping, Quick Changeover, 5S Events, Business CoachingBENDERafter1

Results:

  • Increased production floor capacity by 14,000 sq. ft.
  • Increased throughput 10 to 20%
  • Reduced travel path to bender by 400 ft.
  • Reduced changeover time on one bender by 25%
  • Reduced changeover time on another bender by 42%

Read the full story...


Johnson Electric Coil Celebrates Record Year on Lean Journey

EpoxyProEquipServices: Lean Implementation, Lean Certification of 16 Employees

Results

  • Increased payroll by $800,000 annually
  • Improved safety; saving $50,000/year on premiums
  • Increased annual wages 13% on average
  • Awarded 8% bonus in addition to wages
  • Increased profits by 160% over last year
  • Increased productivity by 15% over last year

Read the full story...


MarquipWardUnited: A Barry-Wehmiller Company

Services: Lean Certificate Training, 5S, Value Stream Mapping, Quick Changeover, Total Productive Maintenance, Cellular FlowAfter_Marquip SS

Results:

  • Increased productivity by 20%
  • Reduced razor tooling floor space by 25%
  • Reduced machine changeover by 50%
  • Reduced circuit test travel path by 49%
  • Decreased knife stiffener set-up time by 75%
  • Reduced month-end closing time in accounting by 25%
  • Eliminated 21 non-value-added accounting activities
  • Reduced custodial storage areas by 50%
  • Reduced motor shop batch sizes by 88%
  • Reduced travel path in motor areas by 93%

Read the full story...


Master Metals, Inc.

Master MetalsServices: Lean Overview with Legos, 5S Events, Value Stream Mapping, Cellular Flow

Results:

  • Decreased work in process by 84%
  • Decreased travel distances by 73%
  • Reduced cart weight from 2 tons to 500 lbs.
  • Achieved goal of completing each job in 4 hours or less
  • Gained 30% production floor space
  • Cost savings of $100,000+
  • Reduced supplier monthly invoices from 100 to 40

Read the full story...


Mastercraft Cleans House and Goes Lean

Services: 5S Events, Value Stream MappingPicture 040

Results:

  • Reduced two set-up times by 50%
  • Increased production time
  • Decreased floor space requirements by 15%
  • Reduced order processing time from 16 days to 4.25 days (73%)
  • Improved employee morale

Read the full story...


Schofield Enterprises

schofield pictureServices: Enterprise Business Transformation Planning Process, Value Stream Mapping, Plant Layout, Cellular Design

Results

  • Lead time reduced by 50% and more
  • Annual cost savings of $200,000
  • Productivity increased
  • Avoided $800,000 in unnecessary investments
  • Reduced parts travel distance by over 50%

Read the full story...


Stainless Specialists, Inc.

StainlessServices: Organizational Development, Change Management, Strategic Planning, Standardized Processes

Results:

  • Implemented a new bid process
  • Created responsibility changes that resulted in a 50% increase in design engineer's time
  • Created a new organization structure
  • Developed a 5-point strategic plan
  • Implemented visual management systems in the tool room

Read the full story...


Stanley Case Works

Services: Lean Manufacturing Overview and Simulation, Lean Value Stream MappingStanley Photo

Results:

  • Reduced processing lead time by 50%
  • Improved profit margin 10 to 15%
  • Reduced WIP inventory from 30 days to 6 days
  • Increased market share
  • Reduced defect rate
  • Increased cash flow
  • Retained 13 employees and added 3 employees
  • Increased sales per employee 20 to 25%

Read the full story...


Tropical Gardens

Services: Value Stream Mapping, Culture of Continuous Improvement, 5S Visual Workplacetropical gardens photo

Results:

  • Productivity improved
  • Reduction in heating costs
  • Improved profit margin
  • Better utilization of floor space
  • More employee involvement
  • Increased morale and pride

Read the full story...


Wisconsin Indianhead Technical College (WITC)

Services: Value Stream Mapping of Admissions ProcessWITC photo

Results:

  • Decreased admission notification from 14 days to 2 days
  • Decreased files accessed from 11 to 6
  • Decreased paperwork time from 9 days to 1 day
  • Increased mailing of matriculation letters from twice a week to daily

Read the full story...


XeteX, Inc.

XeteXServices: Strategy Planning, Milestone Scheduling System, Lean Training, 5S/Visual Systems

Results

  • Implemented a vendor-managed inventory system that eliminates 95% of stock-outs and saves time
  • Developed a scheduling system to enable control of intermediate production milestones that increased quality, reduced costs, and significantly improved on-time delivery
  • 5S Workplace Organization reduced foot travel within the production areas by 240 hours annually and cleaned up the work areas that show well to visiting clients
  • Increased productivity by 10%

Read the full story...