Recent Projects Completed

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.

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.

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.

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.

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.

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.

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.

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.

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

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.

Chemical Mixing/Packaging Operation - Multi-Plant Consolidation

Lean Manufacturing Implementation for Automotive Parts Supplier

Set-Up Reduction for Sintered Metal Products Supplier

Lean Manufacturing Implementation for Brass Components Manufacturer

Set-Up Reduction for Turbomachinery Component Manufacturer

Site Layout for Sprinkler System Manufacturer

Lean Manufacturing Implementation for Spring Manufacturer

Implementation of Work Cells for Saw Blade Manufacturer

Paper Converting Operation - Coating Line Project Management

Office Products Manufacturing Multi-Plant Consolidation

Lean Manufacturing Implementation at Repair Facility for Large Aircraft Engine Components

Warehouse Layout and Packaging Improvement for Urethane Sheet Manufacturing Facility

Site Relocation; Conversion to Cellular Operations for Instrumentation Manufacturer

Urethane Molding Operation Expansion

Steel Foundry Process Start-up

Automotive Rubber Molder Cellular Operations

Paper Converting Manufacturing and Distribution Center

Greeting Card Manufacturing Facility

	Recent Projects Completed

Consulting Plant Layout Services Articles Immediate Impact Training All Training Home Contact Us	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.