Business Issue A global manufacturer of pharmaceutical products was experiencing frequent packaging–line stoppages of a common over-the-counter cough syrup. Production costs had risen to erode margins on this product. Approach Used Flow consultants collected data in which line stoppages were recorded for cause, location and duration. A kaizen team was assembled whose goal was to … [Read more...]
Lean Operations Case Studies
Lengthy Cycle Times and Excessive Inventory
Business Issue Automotive original equipment manufacturer believed that its brake-puller cycle times are far too long and that its inventories are excessive. Approach Used Flow consultants used "Lean" principles and a kaizen session, to move from a process–centered product flow, to a product–focused cell. Results Flow Consulting reduced production costs on a $47 unit by $6.17. They also … [Read more...]
Slow Manufacturing Cycle and High Product Costs
Business Issue Microchip test equipment manufacturer was experiencing high product costs and delivery cycle times exceeding customer expectations. Approach Used Flow consultants implemented comprehensive leadership driven "Lean Enterprise" principles and a series of kaizen sessions with both exempt and hourly personnel. Results The company achieved:
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A 27 percent … [Read more...]
Oil Producer’s Equipment Replacement Increased Duration of Maintenance Turnaround
Business Issue An oil producer was in need of a major capital equipment replacement, which would have caused a costly extension to the duration of a planned maintenance turnaround. The total time for the turnaround needed to be re-planned and the execution managed to ensure the turnaround completed within the budgeted time. Approach Used The Flow Consulting team addressed the problem in three … [Read more...]
High-End Electronics Assembly Product Line Delays
Business Issue A high-end electronics assembly product line was experiencing long lead times, poor delivery performance, and high labor costs. The Fortune 50 manufacturer was experiencing chaos on a critical product set. Evidence of the chaos included the following;
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Low first-time yield
Long and unpredictable lead times
Poor delivery performance
High labor costs
Disappointed … [Read more...]
25 Percent Plant Capacity Increase Needed
Business Issue A 25% increase in plant capacity in less than one year was required by a global provider of oil and gas equipment in East Asia. To help them reach this goal, new leadership asked Flow Consulting to provide guidance and training. Approach Used
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Studied detailed data describing the plant's operation.
Worked with the leadership team to agree upon the correct standards and … [Read more...]