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    Lean Eye

    What Happens When You Ask Why with a Lean Eye?

    A Major US Metal Manufacturer
    The Client Ask:
    Conduct kaizen style event to help improve throughput and increase capacity while achieving cost reductions.
    Plant Attributes at Project Start:
    Recently relocated equipment, multiple sets of common equipment, high volume, high mix, a very competitive industry.
    What We Did:
    Working with the cross-functional client team we studied the product mix to identify dominant products. We then..

    • constructed a high-level current state value stream map
    • calculated surge takt time
    • observed and documented the process continuously for 4-hours with one-second granularity
    • constructed a pareto diagram of wastes observed
    • developed several improved flow concepts
    • asked “Why do we need more than one line?”
    • rapidly prototyped several concepts
    • challenged legacy machine cycle times
    • proved new process several times
    • documented new process standard work
    • trained all area operators on new process.

    The Outcome:
    Over the course of the project, the throughput increased by 20% allowing additional product to be processed on the line without additional assets (equipment or human)

    An increase in capacity of 15+% was realized. The new process configuration removed two process steps which were no longer needed and decreased overall cost by an audited 2%.

    This was a classic flow manufacturing project where we worked together with client team members to address a burning platform. We can do the same for you. We can also assist with larger projects.
    What’s keeping you up nights? Chances are we’ve helped someone tackle a similar issue. We have 40+ years of experience, let us put it to work for you.
    Give us a call to get started. (203) 225-0451. Or email us at

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