Recent Projects Completed

Recent Projects Completed

Cosmetics Manufacturer – Manufacturing Improvement and Quality Systems Deployment

Hired to stabilize and improve contract manufacturers. Set up inspection and audit systems. Implemented work instructions, change control, and paperwork systems. Result has been 60% reduction in customer complaints. Supplier monitoring and control system including report cards resulted in improvement in the quality, delivery, pricing, and support systems of all major suppliers.

Heavy Equipment Manufacturer – Problem-Solving and Mistake-Proofing Training

Developed customized 8-D problem-solving and mistake-proofing training and delivered it at multi-day supplier conferences in the USA, Asia, and Europe.

Government Agency – 5S Implementation

Trained office and warehouse teams on 5S concepts and applied the concepts in training workshops to 8 office departments, laboratory, receiving, and 4 warehouse areas.

Multi-Station Stamping Operation – Set-Up Reduction

Trained teams of automated stamping to reduce set-up times and led those teams to implement changes including activity elimination, conversion of internal time to external time, and balancing of activities that reduced the set-up times by more than 50%.

Automotive Component Manufacturer – Set-Up Reduction

Trained teams of automotive component manufacturer to reduce set-up times and led those teams to implement changes that reduced the set-up times by more than 60%.

Developed and Delivered Customized FMEA Training for Medical Device Manufacturer

Developed Process, Design, and Application FMEA training and delivered this training to help the medical device manufacturer ensure it developed safe products and processes and met FDA requirements.

Development of Quality Systems for Cosmetic Manufacturer

Developed comprehensive quality system from scratch for high-end cosmetic manufacturer. Among other components, the system included management systems, formulation and document control; change control; corrective action process, and supplier audit and evaluation processes.

Scrap Reduction using PFMEA and Poka Yoke for Aerospace Engine Manufacturer

Led series of week-long scrap reduction events at three sites for an aerospace engine manufacturer. Trained multiple teams at each site in PFMEA and basic Mistake-Proofing (poka yoke) techniques. Teams prioritized high RPN failure modes and developed action plans to reduce or eliminate the occurrences of the causes of those failure modes or to improve the controls in place to reduce the detection rating.

Plastic Bottle Manufacturer Downtime/Set-Up Reduction

Trained a master team in downtime reduction techniques and facilitated their application of the tools that resulted in 10 hours of Preventive Maintenance downtime per week being reduced to 2 hours per week. Trained and facilitated the same master team in set-up reduction concepts and facilitated the application of those concepts to high speed blow molding equipment. The planned reductions dropped the set-up times to 1/5 of its original time.

Chemical Mixing/Packaging Operation - Multi-Plant Consolidation

Developed master plan for consolidation of three manufacturing sites into two. Analyzed workflows and plant operations and identified equipment, layout, and operational changes that reduced travel distances by 45% and increased productivity by 33%. When implemented, raw material warehousing practices changes will save reduce floor space by 50% during peak seasonal demands.

Lean Manufacturing Implementation for Automotive Parts Supplier

Trained and led two teams to improve operations for two product lines. Activities included combining and eliminating operations, increasing operational effectiveness, and set-up reduction. The teams continue to work toward their future state maps.

Set-Up Reduction for Sintered Metal Products Supplier

Trained and led a team of operators and supervisors to reduce the set-up times on key presses. Equipment and procedural changes that were made resulted in a set-up time reduction of 74%.

Lean Manufacturing Implementation for Brass Components Manufacturer

Trained and led two teams to improve screw machine set-up times and improve assembly operations for this manufacturer of brass valves. Team identified and implemented set-up changes that decreased set-up times by 69%. Assembly team reduced workflow by 48% and eliminated 20% of the required assembly and testing time.

Set-Up Reduction for Turbomachinery Component Manufacturer

Trained and led two teams of operators and supervisors to reduce the set-up times on CNC machining centers. Equipment and procedural changes that were made reduced the set-up times an average of 62%.

Site Layout for Sprinkler System Manufacturer

Designed cellular layout for new site for this rapidly growing manufacturer. The cells streamlined operations resulting in a 50% floor space savings, 24% labor savings, and 45% cycle time improvement.

Lean Manufacturing Implementation for Spring Manufacturer

Trained and led five teams to simplify operations and design manufacturing cells for key products. Activities included combining and eliminating operations, set-up reduction, line balancing, staffing determination, cost and timing estimation. Results included 18% labor savings, 78% set-up time reduction, and 80% cycle time improvement.

Implementation of Work Cells for Saw Blade Manufacturer

Analyzed workflow and developed process layouts and a scope and cost estimate for converting functional departments into product-family based work cells. Managed the implementation of the cells and brought the project in under budget and ahead of schedule. Cells resulted in 12% labor savings.

Paper Converting Operation - Coating Line Project Management

Managed project to remove two coating lines and replace them with a high speed coater. Project included the coordination of the equipment supplier, general contractors, and customer support groups. Through value-added analysis, the project was brought in under budget for items within the original scope.

Office Products Manufacturing Multi-Plant Consolidation

Developed master plan for consolidation of two manufacturing sites. Included detailed plant layout (with improved workflow), scope and cost estimate for corporate approval, construction grade drawings, time-based project plan and bid package.

Lean Manufacturing Implementation at Repair Facility for Large Aircraft Engine Components

Trained five teams in lean manufacturing concepts including the 5S’s, set-up reduction, and work simplification concepts. Facilitated team activities that resulted in a 70% reduction in the time to develop the repair scope and cost; 50% reduction in machining center set-up time; and an improvement in facility organization and housekeeping. Developed cellular layout that would allow a planned 40% expansion in space to handle a 200% growth in sales.

Warehouse Layout and Packaging Improvement for Urethane Sheet Manufacturing Facility

Analyzed packaging and warehousing operations to identify process and workflow improvements. Based on the analysis, developed recommendations for improvements in the packaging operations and developed a warehouse layout, warehouse equipment recommendations, and a scope and cost estimate for the new warehousing operations.

Site Relocation; Conversion to Cellular Operations for Instrumentation Manufacturer

Designed layout of assembly, test, and packaging operations to convert these operations into product-focused work cells. Activities included work simplification, line balancing, and the preparation of a scope and cost estimate.

Urethane Molding Operation Expansion

Process workflow analysis and plant layout to incorporate new process lines and to improve both effectiveness and efficiency of overall operation. Project included expansion of building and utilities, relocation of existing processes to improve workflow, and modification of supporting quality systems to reflect simplified practices.

Steel Foundry Process Start-up

Process layout and design for casting process and finishing operation using a new proprietary precision shell casting technology. Project included identification of new finishing techniques, process documentation, and development of supporting quality systems.

Automotive Rubber Molder Cellular Operations

Introduced cellular operations to ISO-9001 rubber molding operation. Developed improved plant layout to facilitate reduction in cycle time and labor costs. Created project scope, cost estimate, and justification. Changed work practices leading to improved part quality

Paper Converting Manufacturing and Distribution Center

Designed layout and managed installation of automated packaging lines for high volume roll and sheet product while plant operated at record levels of production. Provided turn-key construction management. Developed process operating procedures and conducted training for manufacturing personnel. Project brought in on-time and under budget.

Greeting Card Manufacturing Facility

Devised a market-driven business unit approach with cellular operations to support it. Reduced manufacturing cycle time by over 70% with a combination of operating philosophy changes, layout improvements, and automation.

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