Featured Projects
Valve Production Facility
Problem Statement – Valve production with existing machining equipment did not satisfy customer demand.
Solution Approach – A series of Lean workshops events were executed in the Mexico facility with crossfunctional teams. Application of Lean tools were used to reduce cycle time and setup time waste.
Results – Cycle times and setup times were reduced on several pieces of equipment, allowing improved productivity and avoidance of $350k in capital expenditure.
Lesson Learned – Employees realized the value of Lean tools such as time study and were excited about applying them on other projects to improve productivity
Sheet Metal Cabinet Assembly Process
Problem Statement – Productivity of cabinet assembly did not satisfy customer demand.
Solution Approach – A Lean workshop was executed with a cross-functional team. Application of Lean tools were used to improve material delivery and reduce assembly time.
Results – Rather than sheet metal components and supplies being delivered haphazardly on skids, several “kitting” carts were fabricated. These carts allowed easier loading for material handlers and easier identification of and unloading of parts for the operators, reducing assembly time and errors in part selection.
Lesson Learned – Employees realized the value of Lean tools such as setup reduction and how they can be applied to material handling and assembly processes.
Packaging Machine - Changeover Time Reduction
Problem Statement – Packaging machine setup times were limiting production and preventing on-time delivery to the customer.
Solution Approach – A Lean workshop was executed with a cross-functional team. Application of Lean tools were used to improve the setup process and reduce assembly time.
Results – The setup procedure was analyzed to understand where motion waste could be eliminated and tooling supplies staged. The setup procedure was standardized to reduce walking distance. Tooling and supplies were situated where operators needed them to reduce motion.
Lesson Learned – Employees realized the value of Lean tools such as spaghetti diagrams and how they can be applied to machine setup processes for elimination of wasted operator motion.
Grinding Machine Setup Reduction and Tooling 5S
Problem Statement – Bearing roller grinder setup times were exceeding standard and production did not satisfy customer demand.
Solution Approach – A Lean workshop was executed in the Stratford facility with a cross-functional team. Application of Lean tools were used to reduce wasted time searching for necessary setup supplies, selecting the correct setup details and completing machine setup.
Results – The setup process was improved to provide a pre-staged setup cart with all necessary supplies, saving operator searching time. The setup instructions were standardized and documented in a database. Tooling cabinets were re-organized using 5S methods and average setup times were reduced by 25%.
Lesson Learned – Employees realized the value of a standardized setup process and pre-staged tooling.
