Lean manufacturing is a business operating system that maximizes customer value while minimizing waste. Lean thinking defines anything that does not add value for the customer as waste. The ultimate goal is to provide perfect value to the customer through a perfect value creation process that has zero waste. Lean manufacturing seeks this goal through waste elimination along entire value streams instead of just isolated points. The creation of new processes that require less human effort, less space, less capital, and less time. Lean thinking will improve the performance of any business in any industry.Your Lean Journey Starts Here.
Congratulations to the latest group of Lean Implementer students who’ve just finished ISI’s 2013 Summer/Fall 5 month course!
34 students from American Airlines, Charles Machine Works, Cookshack, Digital Designs, CMP, American Gaming Systems, ATC Drivetrain, LynnCo Supply Chain, Taylor Industries, Centek, Baker Hughes, Muncie Power Products, Southern Specialties & McElroy Manufacturing were awarded plaques for completion of the course.
The students were required to conduct kaizen events during the course’s duration, and the work done was phenomenal. Some example results were:
Controller Assembly: Build Time: Before- 105 min. After- 40 min. 62% decrease ; Space Used- 28% decrease
1 pc. Flow and Leveling of Powder Coat: WIP: Before- 46 hrs. After- 6 hrs. 78% decrease ; Lead Time: Before- 10 days After- 7 days 30% decrease
Poly Tank Cell: Cycle Time: Before- 6 min. After- 4 min. 33% decrease ; Part Travel: Before- 2,304 ft After- 602 ft 74% decrease ; Inventory: Before- 6 days After- 1.2 days 80% decrease
Great job by all!
Students were asked, “What’s something you got out of the course?”
- “Being able to collaborate with people with different backgrounds, with different companies. It made me look at my processes differently”
- “I finally understand how all the lean tools fit together, and it has made me better able to teach the process.”
- “I think lean naturally, but now I can apply it to many situations. This has been 5 months of a Swiss Army knife of tools to attack waste.”
- “It’s given me the confidence to run events. It’ll be rough at first, but now I know it will be OK.”
- “Inventory: I’d never seen the waste of time and money in inventory and parts before this class, now I get it. We have hundreds of thousands of dollars in material just sitting around.”
Congratulations to our latest Measurable Management Open class graduates! The group of 10 students had some great results from their projects, and are shown after their final project report out with their ISI Instructor, Mark Bradway.
One student said of his projects for the course:
“My first project was my new scheduling strategy that cut 14 days from the process time, and eliminated 56 jobs from W.I.P. The second was on process improvement in the door shop, utilizing one piece flow and yielded a labor savings of $350.00 per day.”
ISI Presents Toyota Kata at Manufacturing Conference
ISI’s Colin Reed presented Toyota Kata at a breakout session last week at the Oklahoma Conference on Manufacturing, put on by the OK Manufacturing Alliance. The session was an introduction and overview of the Toyota Kata methodology, based on the book Toyota Kata by Mike Rother.
The 75 minute session covered background, theory and definitions, PDCA cycles and what Kata programs look like. The presentation will soon be available at: http://www.okalliance.com/2013/10/2013-presentations-and-videos/
See how we can help your company learn and use this method to grow your people and improve your business.
The brochure for ISI’s Kata Introductory Training & Implementation Program can be found at: http://www.isiworld.net/toyota-kata/
ISI Client wins OK Governor’s Manufacturing Leadership Award
Yet another one of Industrial Solutions’ clients has won the OK Governor’s Manufacturing Leadership Award! The OK Manufacturing Alliance and Lt. Gov. Todd Lamb presented the award last week to Oklahoma City based CMP Corporation, a manufacturer and distributer of HVAC and refrigeration compressor parts.
ISI has guided CMP through a complete Lean Transformation of the business. Starting in March 2011, we helped management establish a new strategy of operational excellence based on Lean Thinking and the Toyota Production System. We then began detailed training of the CMP associates, helping them understand and implement the lean tools. It started with basic lean training, using the Lean 101 class, and value stream mapping.
ISI’s facilitation and consulting services guided them through the process, making ideas become reality. A set-up reduction and cellular flow project aligned multiple machines together to produce a product family within a cell. Other initiatives worked on material flow and waste reduction. Meanwhile, select associates were sent through ISI’s 200-hour Lean Implementer course, to become internal Lean Champions.
The company has made significant gains in it’s production processes. One example is the crankshaft value stream: its lead time was reduced from 85 days to just 10 days, and the average cost reduced by 25%.
The OK Alliance write up can soon be seen at http://www.okalliance.com/2013/10/2013-governors-manufacturing-leadership-awards/.
Classes now forming for Track 35 Lean Implementer.
Industrial Solution’s Colin Reed will be speaking on Toyota Kata at the Oklahoma Conference on Manufacturing, on October 9th. The Oklahoma Alliance for Manufacturing is sponsoring the event in Oklahoma City.
McElroy Manufacturing sees great benefits from Industrial Solutions’ led Kaizen Event.
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• All Lean Implementer classes are full! Our next classes will begin January 2014. Schedule coming soon.
• Spanish language classes are now available! For the following workshops:
Congratulations Recent Measurable Management & Lean Implementer Graduates!