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Lean Manufacturing Case Study for Components Company

Technologies:

Forging, casting, machining

Objectives:

Implement Lean Manufacturing Systems and improve delivery performance

As a result of critical customer concerns and customer dissatisfaction, the company engaged Omnex to develop and implement approaches to lean manufacturing through the conduct of specific projects intended to level and synchronize flows, reduce inventories and migrate towards a pull system. Improvements were targeted for rolled throughput yield, overall equipment effectiveness, dock-to-dock, cycle times and delivery performance.

Methodologies involved value stream mapping, constraint analysis and relief, single minute exchange of die (SMED) and quick process changeover; waste, cycle and takt time analyses resulting in leveling and balancing with enhanced flows.

Evidence of success: Delivery performance improved in three months from 15% "on time to promised date" to 60% "on time to customer required date". Correlated metrics showed comparable, sustained improvement.

To find out more about Omnex's workshops and consulting services in Breakaway Lean®, Excelerated Six Sigma® or Unified Lean/Six Sigma™ please contact:

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Omnex Business Development
(734)761-4940
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