Client Success: People and Culture
Action Floor Systems Begins Lean Journey
Services: Lean Certification Training, 5S Events, Value Stream Mapping
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
Services: 5S Visual Systems
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
Services: Six Kaizen Events
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
Atlas Resin Proppants Believes Good People are Key
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
Services: Principles of Lean Workshop, Value Stream Mapping, 5S, Design and Implementation
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
Services: Value Stream Mapping and Implementation, Current State Mapping -- Future State Mapping
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
Services: Lean with Legos, Value Stream Mapping
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
FM Enterprises
Services: 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
Handishop Industries Keeps Tools Handy
Services: Lean Manufacturing, 5S, Value Stream Mapping
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
Services: Cellular Plant Layout with Flow Seminars
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
Johnson Electric Coil Celebrates Record Year on Lean Journey
Services: 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
MarquipWardUnited: A Barry-Wehmiller Company
Services: Lean Certificate Training, 5S, Value Stream Mapping, Quick Changeover, Total Productive Maintenance, Cellular Flow
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%
Services: 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
Mastercraft Cleans House and Goes Lean
Services: 5S Events, Value Stream Mapping
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
Services: 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%
Services: 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
Services: Value Stream Mapping, Culture of Continuous Improvement, 5S Visual Workplace
Results:
- Productivity improved
- Reduction in heating costs
- Improved profit margin
- Better utilization of floor space
- More employee involvement
- Increased morale and pride
Services: 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%