Client Engagement Summaries For over 30 years, we have been helping organizations build their Lean capabilities.  We have worked throughout the Global 1000 in a broad-breadth of operating environments, from traditional manufacturers to financial and service organizations, from oil fields and off-shore oil platforms, to gold mines, shipping ports, and bio-medical laboratories. Whether you are looking for one day of on-site consulting, help assessing your progress, training in the key Lean techniques, or facilitation of a global rollout, Productivity has the experience and industry expertise to help you improve your organizational capabilities and get and stay Lean.    Click on the links below for a sampling of engagements and implementation projects.

Engagement Objectives

Implementation of Visual Workplace

Organization: Global 1000 Aerospace & Automotive Manufacturer/Supplier

Engagement Duration: 2 Years, 10 Facilities

Engagement Objectives: Implementation of visual workplace

Major Project Activities:

• Visual workplace overview to strategic business unit’s executive sector
• 20 training events at multi-plant sites: 5S, visual display, and visual control
• Post-training site implementation coaching, audits, and project management
• Certified 10 Visual Workplace trainers
• Visual office training and site specific implementation coaching and consulting




Key Outcomes: Reduced non-value adding floor space up to 50%, reduced non-value adding search time up to 50%, direct supporting role in the reduction of total inventory by 70% and manufacturing cost by 40%. Positive impact on morale and employee empowerment.

Implementation of Lean Manufacturing

Organization: Global 1000 Sport Footwear, Apparel, and Hardware Manufacturer

Engagement Duration: 5 years

Engagement Objectives: Implementation of Lean manufacturing within select first and second tier suppliers (Global)

Major Project Activities:

• Design of a customized 4 week (footwear) and 3 week (apparel) Lean Managers Certification Program tailored to the client processes and cultural considerations
• Global training of trainers; plus training of +150 managers and Lean manufacturing champions
• Facilitated Lean implementation at sites located in China, Southeast Asia, Europe, Mexico and North Africa
• Site audits (global) with action planning, counter-measures, and extensive follow-up process improvement consulting




Key Outcomes: successfully positioned internal capabilities, work-in-process reduced by 70%; dock-to-dock improved by 80%; defects down by as much as 90%; lead time reduced by 75%.

Overall Cost Containment

Organization: Leading Producer of Plastic and Metal Packaging

Engagement Duration: 3 Years, 2 Facilities

Engagement Objectives: Overall cost containment. Reduce cost of goods sold by 20% with resulting capabilities to sustain and grow

Major Project Activities:

• Operations assessment, detailed lean conversion plan, Lean awareness seminars and a series of management Lean educational events
• Continuous flow implementation, select Lean tools training for entire work force, and facilitated numerous kaizen events
• Total Productive Maintenance Implementation
• Coach, mentor, and assist in the implementation process




Key Outcomes: achieved cost of goods target in the first 12 months; targeted equipment output up 60%; set-up time reduction ~65%; positioned a visual factory; training of critical mass in cause and effect, process variation reduction

Custom Total Productive Maintenance Train the Trainer Certification

Organization: World’s Largest Chemical Manufacturer

Engagement Duration: 18 Months, 2 Strategic Business Units, 5 Major Facilities

Engagement Objectives: Focused TPM/AM training of trainer certification

Major Project Activities:

• Design and delivery of a custom Total Productive Maintenance trainer certification program
• Certified 30 employees as Automomous Maintenance (AM) trainers
• Facilitated and coached visual workplace and targeted changeover reduction (SMED) small group projects




Key Outcomes: positioned internal AM capabilities; established base-line Overall Equipment Effectiveness (OEE), established process to monitor and measure OEE at the equipment level, audit counter-measure process

Reduce Manufacturing Lead Time

Organization: Leading Manufacturer/Distributor of Office Specialty Products

Engagement Duration: 12 Months

Engagement Objectives: Reduce manufacturing lead time 20% for all core products

Major Project Activities:

• Extensive operations assessment with remedial actions
• A series of Lean management trainings for 20 Managers
• Critical mass employee training in Changeover Reduction (SMED), Cell Design and Visual Workplace. Facilitated numerous kaizen events
• Established audit process with counter-measures checklist
• Prescriptive consulting, coaching, and mentoring activities




Key Outcomes: Core products lead time cut by >25%, changeover reduced by 90% on target equipment, overall output up 20%, and seasonal demand met without increasing labor cost.

Achieving Zero Defects (Mistake Proofing) Trainer Certification

Organization: Global 1000 Telecommunications Equipment Manufacturer

Engagement Duration: 2 Years

Engagement Objectives: Achieving Zero Defects (Mistake Proofing) training, implementation and trainer certification

Major Project Activities:

• >400 employees trained in Mistake Proofing methodology
• Certification of internal Mistake Proofing trainers




Key Outcomes: >$2.5 million reduction in manufacturing cost directly related to mistake proofing implementation. Recipient of the Deming Prize for Product Quality

Implementation of Lean Production and Lean Office

Organization: Major Manufacturer of Specialty Hose and Hose Fittings

Engagement Duration: 4 Years, 6 Facilities

Engagement Objectives: Position Lean manufacturing improvement methodologies in production and the office environment

Major Project Activities:

• Improvement strategy planning and deployment
• Extensive employee training in Lean improvement techniques
• Site-specific plant layout reconfiguration and streamlining
• Team leader training
• Facilitated numerous production and office kaizen events
• Project management training and coaching
• Manufacturing Support (office) waste elimination program: value stream management, mistake proofing, problem solving, 5S, and flow




Key Outcomes: key value stream lead times reduced by 30%, non-value adding floor space reduced by 25%, value adding ratios improved 500%, changeover improved ~50%, order entry time reduced ~30%

Implementation of Lean Business Processes

Organization: Major New England Newspaper Company

Engagement Duration: 3 years

Engagement Objectives: Implementation of Lean business processes

Major Project Activities:

• Positioned strategy, planning, and policy deployment process
• Implemented a project chartering and project management process
• Curriculum design and delivery of a Lean Leaders Certification Program
• Numerous Lean tool training events (critical mass)
• On-site coaching, a Training-of-Trainers Program, and an audit process




Aggregate Audited Outcomes: Confidential

Build Internal Lean Production Resource Capabilities

Organization: Global 1000 Diversified Manufacturer of Technical Products

Engagement Duration: 3 Years

Engagement Objectives: Build internal Lean production resource capabilities

Major Project Activities:

• Design and delivery of a customized 4 week Lean Champions Training
• Training of +300 Lean Champions: China, EU, Mexico, and USA
• On-site auditing, coaching, mentoring, and project management activities




Key Outcomes: On-time delivery improvements of +90%, inventory reductions of more than 80%, administrative process cycle time reductions of +80%, dock-to-dock key value stream improvements of 70%.

Build Internal Lean Operational Resource Capabilities

Organization: Leading Biotechnology Company

Engagement Duration: 3 Years

Engagement Objectives: Build internal Lean operational excellence resource capabilities

Major Project Activities:

• Design and delivery of a custom, three-tier, Lean Champions training program tailored to the office/research/transactional environment
• Executive coaching on leading and managing in a Lean environment
• Design and delivery of an extensive Total Productive Maintenance based equipment reliability training program




Key Outcomes: Confidential

Implementation of Lean Production

Organization: Major Automotive Supplier, Machine Tools/Fabricator

Engagement Duration: 1 Year, 4 Facilities

Engagement Objectives: Improve Lean manufacturing practices and capabilities

Major Project Activities:

• Corporate, plant manager and staff training in Lean management
• Operations assessment and Lean program planning
• Redesign of manufacturing and distribution software programs
• Established supplier performance measurements and ratings
• Employee training and implementation: Changeover Reduction, Visual Workplace, TPM, Cell Design, and Kanban




Key Outcomes: On-time delivery from 30/60% to 92%, supplier performance rating up 30 points, set-up reductions ~65%, major infra-structure design changes creating needed flexibility.

Lean Supplier Training

Organization: Global 1000 Automobile and Truck Manufacturer

Engagement Duration: 5 years

Engagement Objectives: Lean manufacturing capabilities training with first and second tier suppliers; global deployment of production metrics

Major Project Activities:

• Member of Lean Resource Center Advisory Group
• Provide strategic direction for ‘Production System’ design and policy
• Provide expertise, resources and training materials to Resource Center Lean training curriculums
• Logistics and on-site global delivery of 3 day Lean Manufacturing Awareness sessions
• On site Resource Center Lean training of suppliers




Key Outcomes: Confidential

Global Implementation of Quick Changeover (SMED)

Organization: Leading Manufacturer of Consumer Products (Hygiene-Infant Care)

Engagement Duration: 5 years

Engagement Objectives: Achieve minimal changeover/make-ready time on all product lines, consistent with high quality standards, and at the lowest possible cost

Major Project Activities:

• Developed customized workshop training materials
• Delivery of 200+ Achieving Quick Changeover (SMED) Workshops
• 3000+ employees trained throughout Asia, Europe, South America, and USA




Key Outcomes: Confidential

Autonomous Maintenance Certification

Organization: Major Manufacturer of Industrial and Communications Wire and Cable

Engagement Duration: 18 months, 3 Facilities

Engagement Objectives: Deploy company-wide Autonomous Maintenance effort and internal trainer certification (Total Productive Maintenance)

Major Project Activities:

• 4 Total Productive Maintenance Leadership [Management] Workshops
• 150 employees trained in Autonomous Maintenance
• Certified 4 Autonomous Maintenance Trainers




Key Outcomes: Mean-time between failures (MTBF) improved 48%, overall equipment effectiveness (OEE) from ~48% to ~70%, wire breaks @ 5 per shift reduced to 3 breaks in 3 months, numerous equipment redesign projects.

Stabilize and Reduce Maintenance Cost

Organization: Large Chemical Mining Operation

Engagement Duration: 2 Years

Engagement Objectives: Stabilize and reduce maintenance cost. Improve overall productivity.

Major Project Activities:

• Facilitated Total Productive Maintenance (TPM) Action Planning
• Certified 4 TPM/Autonomous Maintenance trainers
• Prescriptive consulting and coaching in storeroom redesign, maintenance scheduling and work order systems, maintenance auditing, and quick changeover (SMED) principles




Key Outcomes: Maintenance cost stabilized. productivity [sales per employee] improved by 30%, $1.6 million energy savings [leaks eliminated].

Implementation of a Lean Production System

Organization: A Major USA Aluminum Manufacturer

Engagement Duration: 3 years

Engagement Objectives: Implementation of a lean production system

Major Project Activities:

• Strategy, planning, and policy deployment processes
• Project management process
• Certified 60 Lean Leaders
• Lean sigma training: beginner-intermediate- advanced
• On-site [12 locations] implementation coaching, tool specific employee training, project team facilitation, and audit process




Key Outcomes: Confidential

Establish and Optimize Call Center Process Flow

Organization: A Major European Insurance Organization

Engagement Duration: 2 Years

Engagement Objectives: Establish and optimize call center process flow

Major Project Activities:

• Training in DMAIC process, Lean principles and 5S
• Identified key performance indicators and performance review process
• Established a high-performance (team-based) organizational structure
• Determine, document, and communicate standard work




Key Outcomes: Reduced document stock 45%, standard work established and practiced, problem solving process established and used, team members cross trained in multiple department functions, increased overall productivity +20% in first 3 months and +40% to date.

Sample Transactional Projects

• Reduced worker compensation cost by $750,000 per year
• Cut account receivable process time by 33%
• Increased quotation capacity by 40%
• Reduced IT support action item closure time by 25%
• Reduce account receivable and account payable labor cost by 30%
• Implemented a direct communications program to continuously broadcast company DNA
• Reduced product development quotation time from ›3 to ‹1 day
• Reduced Design Engineering time-to-market from 224 hours to 50 hours
• Shortened the product engineering order processing time from 17days to 8 days
• Reduced invoicing process time from 22 hours to 8 hours
• Cut the ordering processing time for key customer components by 60%
• Reduced global sales order quotation and order entry process from 10 days to 3 days
• Month-end trial balance (closing) from 5 days to 2 days
• New product launch from 55 days to 15 days
• Reduced customer pricing revision procedure from 77 days to 2 days
• Sales order through engineering design and pre-trial process from 5 days to 1 day

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