Lean Operations Case Studies
Unleashing Potential Using Lean Techniques
Business Issue Our client’s very low production volume failed to meet the needs of its customers to provide laser engraving on a variety of drink ware products. Production volume was running at 66,000 units per month against a target of 500,000 units per month. Other key metrics included the following:
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Drying time of the paint-like product exceeded the 2.5 hours promised but instead … [Read more...]
European Manufacturer Losing Market Share
Business Issue A European manufacturer of high-end industrial machines was losing market share because of unacceptably long lead times. Approach Used Flow Consulting rolled out an extensive Lean program combining both projects and internal training, utilizing key Lean tools focused on set-up reduction, 5S, facility layout based on process flow, and one-piece flow. Results Lead times have … [Read more...]
Assembly Site Production Consolidation
Business Issue A highly technical assembly site needed to consolidate production from two buildings to one while shifting some simple assemblies to third-party providers. Approach Used Flow Consulting coached and facilitated the training of 10 Lean Black Belts and 20 Green Belts — and to consult on design and implementation, which included:
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Five hands-on Lean training … [Read more...]
Factory Lead Times Exceeded Customer Requirements
Business Issue A turbine blade manufacturer in support of maintenance, repair, and overhaul of gas and steam turbines was experiencing factory lead times that exceeded customer requirements. This manufacturer supports turbine outage/turnaround repairs, which means that short and predictable manufacturing lead times are critical. Approach Used Flow Consulting worked with a … [Read more...]
Reducing Manufacturing Costs
Business Issue Pharmaceutical company facing significant challenges to cut its manufacturing costs. Approach Used Flow consultants performed an "Accelerated Problem Solving" workshop to analyze processes and quickly find and deliver opportunities for yield–improvements in mixing and packaging processes. Results Within two weeks the Flow workshop delivered $75,000 in annualized savings and … [Read more...]