Corporate Improvement Initiatives: Example Projects
A Design and Manufacturer of Industrial Products with 4000 Employees
A Design and Manufacturer of Industrial Products with 4000 employees was facing stiff competition from off-shore companies. Products were primarily high volume commodity components with some product families engineered for specific customer requirements.
We created a corporate Lean Sigma program, deployed at multiple plants with a unique train/apply methodology. The program was comprised of Lean Enterprise per TPS, Six Sigma and Maintenance Excellence. Focused training and projects included administrative and engineering design processes.
Two hundred lean masters were trained and applied the tools to carefully selected project then to their day to day jobs. Over 1000 kaizen events were held supporting multiple projects resulting in cycle time reductions of 40% to 80%, lead time reductions of 40% to 88%, and reduction of total manufacturing costs of 8% to 20%.