Lean Manufacturing Case Studies

LEAN Manufacturing Training, Mentoring and Coaching

LeanPlus™ provided:

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:

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

LEAN Manufacturing Training/Mentoring

LeanPlus™ provided:

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

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

LeanPlus™ provided:

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