Completed SMED training and a week-long SMED event resulting in a list of improvements and a defined process to cut 60% off changeover times (75 minutes to 27 minutes)
Facilitated a week-long kaizen event resulting in >$40,000 annual labor savings as well as improved material flow, reduced defects, and reduced material storage costs
Developed two facility layout options to improve effective overall floorspace by 12% at a cost of only $11/sqft. These layouts would result in more than $74,000 in annual savings from reduced material handling and increased productivity, representing a 9 month payback period.
Utility Equipment Manufacturer
Trained executive and management team on lean manufacturing principles with in-depth review of 5S and PDCA
Implemented 5S in the warehouse/stockroom resulting in a 50% reduction in floor space usage.
Completed a weeklong kaizen event resulting in 25% reduction in paint prep labor and improved material handling
Completed a value stream mapping event resulting in a 12% reduction in lead time without any capital expenses and a roadmap to achieve a 65% reduction in lead time
Implemented kanban system for inventory management resulting in a drastic improvement of “in-stock” SKU’s (55% of product was out of stock before implementing kanban, <10% within 6 months of kanban start)
Completed kaizen even resulting in >30% increase in orders shipped per hour ($30,000 cost avoidance)
Completed work cell design projects which reduced floor space usage by 35% and a productivity increase of 15%
Developed quick changeover methods to reduce loom changeover time by 2 hours, a 40% reduction
Natural Gas Compressor Refurbishments
Developed standardized work for a new product while reducing build time by 25% through improved processing and tools
Standardized work documentation required nearly 100 pages of material documenting each step with key points, safety concerns and quality requirements
Sign Wire and Roll Form Manufacturer
Completed “5S for Manufacturing” training for 20 employees from various functions
Facilitated 3-day 5S event resulting in drastic visual control improvement, a reduction in floor space (30% reduction for one process alone) and process improvements resulting in a 10% increase in productivity for one process
Completed full-day “Intro to Lean Six Sigma” for management team
Developed procedures and software configuration to manage sales contracts
Completed facility analysis to improve material flow.