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Case Studies

CASE STUDY #1:
AVIATION PARTS MANUFACTURER , USA

February - December, 2003:
LEAN Manufacturing Training & Mentoring/Coaching

LeanPlus™ provided:

2-Day Executive Lean Training
5-Day LEAN Implementer's Course
Rapid Improvement Process

An aviation parts manufacturer who provides parts for Boeing and Lockheed Martin used training to start their culture change to Lean Manufacturing and immediately saw results. Their executives attended a 2-day class and 15 key managers attended a 5-day class to start their Lean manufacturing journey. Within two weeks after class, the following improvements were made:

TUBE BENDING SHOP TEAM:

60% Reduction in Material Handling
15% Productivity Increase

MANUFACTURING SUPPORT TEAM:

Reduction of 29 miles of walking
60% Change-over Time Reduction

CNC MACHINE SHOP TEAM:

75% Set-up Time Reduction
25% Machine Utilization Increase

THE RESULTS ...

$346,000 First Year Cost Reduction
5:1 Return On Investment
Over $200,000 Second Year Savings

CASE STUDY #2:
MEDICAL DEVICE MANUFACTURER , USA

November, 2004 - April, 2005:
LEAN Manufacturing Training/Mentoring

LeanPlus™ provided:

2-Day Executive LEAN Training
5-Day LEAN Implementer's Course
Rapid Improvement Process

A medical device manufacturer that needed to double production in the next 12 months wanted to remove roadblocks that were preventing smooth production flow and increase efficiency.

LeanPlus facilitated eight (8) RIP events that provided a new layout and removal of hidden wastes after laying the ground work with training for the implementers and senior staff members:

THREE KEY IMPROVEMENTS WERE:

Work-in-progress was reduced by 80%
Buffer stock reduced from 5 days to 1 day
Overtime was reduced by $31,000

THE RESULTS ...

$237,000 Annual Operational Cost Savings
Over $1 Million Employment Cost Savings (avoided need for 2nd shift of labor)
12:1 Return On Investment

CASE STUDY #3:
HEAVY EQUIPMENT MANUFACTURER , INDIA

June, 2005 – December, 2006:
LEAN Manufacturing Training/Mentoring

LeanPlus™ provided:

2-Day Executive LEAN Training
6-month Certified LEAN Expert Training
3 Rapid Improvement Process (RIP)

A heavy equipment machine manufacturing division that makes small quantity of large machines for global market sales needed to REDUCE CYCLE TIME to meet customer demand. LeanPlus™ facilitated a 5-day RIP event that provided a new layout and removed hidden waste.

THE RESULTS ...

Process cycle time reduced from 41 days to 29 days (29% reduction)
1st year savings of Rs 22 Lakhs and increased sales potential of Rs 2.56 Cs in 5 days

CASE STUDY #4:
PHARMACEUTICAL MANUFACTURER , INDIA and SRI LANKA

August, 2001 – July, 2002:
LEAN Sigma Training/Mentoring

LeanPlus™ provided:

6-month Lean Expert Training Course
6 months of Mentoring/Coaching

A pharmaceutical manufacturing company used Lean Manufacturing Practices and Six Sigma techniques to:

Reduce scrap/waste from 6% to 1.5%
Savings was equal to 5.7% of their annual sales after just 9 months
More than 14 "just-do-it" projects identified and implemented by shop floor personnel

September, 2001 – June, 2002
LEAN Sigma Mentor/Coach

A nutritional food supplement manufacturing company used Lean Manufacturing Practices and Six Sigma techniques to change their layout and improved processes.

THE RESULTS ...

5.7% production increase
Savings was equal to 6.1% of their annual sales after just 9 months

CASE STUDY #5:
TITANIUM PARTS MANUFACTURER , RUSSIA

October, 2004 - January, 2005:
LEAN Manufacturing Mentoring/Coaching

LeanPlus™ provided:

4-month Certified LEAN Manufacturing Expert Training
3 Rapid Improvement Process (RIP)

A titanium parts manufacturer who provides parts for Boeing and Lockheed Martin aircraft, Rolls Royce and General Electric engines used training to start their culture change to Lean Manufacturing and immediately saw results.

Their 6-person team identified production bottlenecks and then removed them. They wrote new operating procedures and trained the workers. Within 2 weeks following the RIP, these improvements were made:

KEY IMPROVEMENTS WERE:

Productivity increase 18% from 64 to 82%
Change-over time reduced 83% from 30 minutes to 5 minutes

THE RESULTS ...

Value of 1st year increased production
$3.3 million (USD)
300:1 Return On Investment

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