Selected improvement results delivered within multiple industries:
Medical device manufacturer attended our 4-day 5S training workshop. Their team of 15 people implemented 5S within three (3) different areas within their service depot, reducing about 33%.
Paper towel and tissue manufacturer attended our 2-day setup time reduction workshop. The Converting side of their business reduced their very complex changeover process 33% (3 hours to 2 hours).
Custom blow mold manufacturer: Two (2) teams attended our 2-day setup time reduction workshop. One team reduced 3,200 feet of motion and transport waste over 50% while the second team reduced their setup times over 45%.
Printing division (11 presses) for major custom plastic packaging corporation has reduced setup/changeover times from over two (2) hours to less than 30 minutes in 8 months.
Multiple flexography label printers and converters---improved throughput ranging from 46% to over 300%.
Metal fabrication (HVAC) manufacturer: 20%+ increase in output for $50MM multi-plant organization within 60 days and, applying SMED techniques, decreased setup times over 25%.
Coated paper and films manufacturer: $24MM accounts payable goods received not invoiced (GRNI) process improvement project, including process mapping, conducting Kaizen Events, and resulted in reducing match exceptions by $6MM+.
Multi-state $50MM logistics organization: improved work flow and reduced turnaround time to identify daily brokered routes by 25%/day.
Credit card manufacturer: Improved on-time deliveries from 45% to 80+% within two months using capacity-driven demand management and mobile pull-based supermarkets.
Consumer packaged goods: Implemented visual Lean Manufacturing tools, reducing scrap 40% within four months.
$400 million MRO Distributor: Reengineered forecasting, replenishment and procurement processes for 11 Distribution Center network with 250,000 items. Improved inventory turns from three to five within six months, reducing inventories from $28 million to $23 million.
Consumed packaged goods: Increased output from 11,000 pcs/shift to 70,000+ within 6 months on high-volume blister-pack machine.
Consumed packaged goods: Increased distribution center throughput by 25%, improved stock rotation, improved order accuracy by 20%, and increased capacity without expanding distribution center.