Client Success: People and Culture

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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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%

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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

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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

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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%

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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

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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

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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%

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