Client Success: Top-Line Growth

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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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

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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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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

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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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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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