Helping You Solve Your Lean Manufacturing Problems

Do you have any of these problems

• Excessive time & cost for setup/changeovers

• Some work centers overloaded, some under loaded, causing poor utilization of people, disjointed flow and capacity bottlenecks

• Unexpected downtime resulting in schedule disruptions and expensive avoidable repairs                  

• Excessive number of non value adding steps causing  inflexibility, long lead times and waste

• Complex scheduling system resulting in slower product flow, excessive paperwork & transactions and no visual controls

• Constant material and capacity shortages causing poor customer service, missed deliveries, and expediting 

• Kanbans or Demand Pull signals that result in  excess inventory or late deliveries

• Quality problems that interrupt the flow  

Learn the secrets to getting these kinds of results (results are from our clients):  

• Inventory down 40-75%

• Work-in-process inventory reduced by 78%

• Cost of sales reduced by 20% in a single year following system implementation

• Mfg. cycle time reduced by 40 - 60%

• Manufacturing cycle time reduced 50% or more on all lines

• Production floor paperwork and transactions reduced by 75%

• Demonstrated capacity increased by 15%

• Unplanned downtime reduced by 50%

• Setup/changeovers reduced by 25% without additional working capital

• Productivity up 85-100%

Typically our clients have worked on the following areas to show the kinds of improvements listed above:  

• Upgraded sales and operations planning processes to ensure resources - key materials, people and equipment - are available at the right time to execute a lean strategy.  

• Better master scheduling and leveling techniques to achieve production stability.  

• Improved scheduling mechanisms including load leveling boxes to communicate finishing schedules to the key pacemaker processes.  

• New lean strategies for producing to customer orders or to finished good supermarket replenishment signals rather than to forecasted demand.    

• Focused setup time reduction programs to increase plant flexibility and reduced production intervals.  

• Improved statistical process controls and other quality techniques to reduce variability and eliminate scrap.  

You can find additional information about these problems and their solutions here at this website in the following places: 

Articles

• Gaining a Competitive Advantage with Synchronous Flow Manufacturing

• Demand Pull (Pure Kanban): What are the Prerequisites for Success?

• Dayco Finds Continuous Improvement Is The Way To Go

• Japanese Style Execution vs. American Style Planning!

• Consider These Questions Before Changing the Master Production Schedule

• Class A Regained at Dade Behring

• Getting Started With Sales and Operations Planning

• Making More With Less Is Lean Manufacturing

• Are You Really Ready for Lean Manufacturing?

• Master It (Master Scheduling and Lean Production)

Tailored classes and workshops

• A solid, well-planned program of tailored, on-site education

• Tailored education methodology

Consulting and assessment

• Objective assessment of strengths, weaknesses, and opportunities for improvement

• Tangible improvements and financial results as you go

You can get personalized help.  If you would like to discuss your company's situation in more detail, you can send a question or comments to one of our Senior Partners using the form below, or you can call directly. 

John Civerolo ( 1 505 341-0845)

John Dougherty (1 603 528-0840)

Chris Gray (1 603 778-9211)

Don Rice (1 615 221-2196)

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