Continuous Improvement Services
Improve Productivity, Reduce Defects, Improve Lead-times, Deliver On-time, Reduce Inventory and Gain a Competitive Edge

Lean Transformation

We will find the waste that exists in your company and work with you to reduce it, or better yet eliminate it! Every dollar manufacturers lose from inefficient or ineffective operations is multiplied on the bottom line and every bit of unrealized capacity can mean lost sales and profits. Lean is not optional in today's business world, it is a requirement.

We offer services for every manufacturer at every stage of the lean journey. And, Lean Transformation is a never ending journey. At the beginning of your journey you become aware of lean benefits and lean tools. Next you focus on projects that solve problems processes to understand why they fail. Our approach takes you through this multi-phased and multi-focused process. We look at overproduction, processing, motion, inventory, transportation, defects, waiting and under utilized people in your shop operations, in your office procedures and in your supply chain. We build a lean program that is designed for the unique aspects of your organization and we train your people to execute the program over time. By working with your leadership team, we help you build the Lean infrastructure required to develop and sustain the continuous improvement culture which will separate you from the competition. The methodology known as Hoshin Kanri or Policy Deployment is a key component of our methodology that establishes this culture of improvement.

Six Sigma

We have trained Black Belts who use the Define, Measure, Analyze, Improve, and Control (DMAIC) methodology and six sigma tools to reduce variation in processes. This methodology uses a variety of tools at each step. Six Sigma is a good approach to solve process variation problems when: the causes of the situation are unknown, the problems are commonplace but not well defined, when other approaches are inappropriate or ineffective, or when the situation is complex with many variables. A six sigma process yields 3.4 defects per million products manufactured which means that 99.99966% of the products manufactured are expected to be free of defects.

Plant or Process Layout

Manufacturers often need to re-layout or relocate their facilities or operations. When this occurs the objective should be to leave behind existing inefficiencies, and to streamline front office, warehousing and manufacturing operations. Often the existing location ( if a re-layout) or the new location (if a move or a startup) requires extensive building alterations. We work closely with the manufacturer, in an iterative process, to develop and analyze alternative layouts to improve operations using Lean principles for eliminating waste, accelerating throughput and increasing productivity. The new layout then works as the baseline for the architectural design of the building and site. This solution provides the manufacturer with the key information needed to cost effectively work with the architect, building contractors and others to successfully complete the project. Having a well organized facility with improved process flows sets the foundation for further Lean Transformation efforts.

Quality Systems

Implementing Quality Management Systems like the ISO 9000 family of standards (including TS 16949 for Automotive and AS 9100 for Aerospace related products) are known to improve a manufacturer's business, often having a positive effect on investment, market share, sales, margins, competitive advantage, and litigation avoidance. In many cases it is a requirement for doing business and often with customers overseas. In each of the cases we can help you with planning, training and support as you implement these standards in your company sot that you will be in compliance with the standard and will be prepared for your registration audit.

Training Within Industry (TWI)

TWI was a precursor to Lean and our experts can be used to enhance your continuous improvement efforts with TWI. TWI was developed by the US Government during WWII to help organizations respond to the high rate of employee turnover they were experiencing as a result of the war. TWI is not only about training employees to get them up to speed faster, it includes a focus on improving job methods, and relations between employees and supervisors providing a focus on people as individuals.

Lean Sigma

We integrate our Lean Transformation and Six Sigma services to improve flow and reduce variations. Lean is about continuous improvements to produce necessary items in the necessary quantities at the necessary time without waste. It is designed to produce quality at the source, to provide fast response so that production can match demand and it provides a respect for humanity. Six Sigma reduces variation in a process through focused projects that improve key metrics. It strives to create predictable processes (defect reduction) that consistently meet customer requirements without waste. Combining Lean Transformation with Six Sigma expands the effectiveness of a Lean Transformation program.

Lean and Green

We also integrate our Lean and Sustainability services. Today more and more manufacturers want to include their efforts to eliminate (Refuse),
Reduce, and Reuse or Recycle (4R) WASTE (Water, emissions (Air),
Solids, chemicals (Toxicity) and Energy) in their facility with their Lean Transformation effort. Our Lean Transformation services are designed to integrate our Lean and Sustainability capabilities so your company is Lean and Green.

MAP Services:

• Continuous Improvement
• Supply Chain
• Sustainability
• Workforce