case studies

A major whirlpool tub manufacturer implemented Lean and 5S in their production areas to improve product flow increase capacity. Over 50% of the production floor was 5S'ed, rearranged for Lean one-piece flow, and production capacity was tripled with minimal expense. Productivity was increased over 40% and their customer satisfaction is reflected in a doubling of orders. Current project focuses on realigning the remaining production areas to similar results. Classes and implementation labs are conducted in both English and Spanish.

A leading candle and wax company implemented Lean through their operations, streamlining the flow of work and simplifying methods and procedures. We conducted front line Supervisory training and organized their supervisors into Lean teams. These teams were able to reduce production space requirements over 50% and to consolidate production from two buildings to one.

Classes and labs were conducted both in English and Spanish.

A producer of high-pressured cylinders completed a 6 Sigma class where they identified critical customer criteria and implemented a wide variety of improvements. One team was able to reduce the order processing time from an average of 20 days to less than 48 hours.

At an automotive parts manufacturer, supervisors and leads used Lean methods to improve both office and production communication and order flow. One team implemented an improved process of controlling vendor material that resulted in significant profit improvement (over $1,000,000 per year). All classes were conducted in Spanish.

At a manufacturer of specialized lighting, we first trained and then implemented a Supply Chain and ERP system. By implementing both ERP and Lean they were able to improve their on-time deliveries from less than 50% to over 97%. Assembly and fabrication production flows were realigned to accomplish a Lean pull flow. Product cycle time was reduced over 70% with a corresponding increase in productivity.

At a major parts producer for the telecommunication industry, we assisted their management team in their implementation of Lean thinking. One Engineering team was able to reduce new product introduction from eight months to less than two months. A production team was able to reduce metal waste on one machine by over $60,000 a month and then reduced overall organizational metal waste over 40%.