Some examples are shown of Shop Floor improvements undertaken by us to support clients. The experience is that the best results are obtained when a Top Manager from the client is elected as the “Sponsor” of such a project. Teams were usually made up of one or two Crosstown Power consultants and a small team of shop floor operatives and their supervisor from the clients side. Having the Quality responsible in the clients team also drives a successful project.
Manufacturing Facility in Russia
This was a large multinational corporation with premier manufacturing facilities in Russia. The factory and supplier structure was analysed and implementation plans delivered within four months. All aspects of Lean/Six Sigma were implemented over an 18month project duration. The project is now completed successfully and the client is now in the execution phase including a re-design of factories and organisation. Cost reductions of up to 40% and lead time reductions of a factor of 3 have been demonstrated through internal measures. We deployed a team of 5 top professionals ranging from General Management, Finance, Quality, Manufacturing, Lean/Six-Sigma and Human Capital areas for this project.
Excessive Processes Reduced Lead time reduced by a factor of three.
Reduced rework and Quality
improved. Zero Scrap.
New Factory Design & Lean/Six-Sigma Implementation
This was a major manufacturing base improvement with five senior experts being deployed over a period of four years. The entire factory structure was re-designed and a new factory designed and built during the 2007-2008 period. Major new investments were acquired. Lean/Six-Sigma principles and JIT were implemented in the new factory. Existing factories were merged into the new facility and equipment re-positioned to ensure a full Lean Enterprise was set-up. On-Time-Delivery improved from 87% to 98% and Cost of Poor Quality reduced to low single digits (revenue basis).
Factory Layout
WIP Reduction
Manufacturing Technology + Lean/Six-Sigma
Manufacturing technology projects have also been implemented as part of our overall Lean/Six-Sigma program. This example shows process automation utilising state-of-the-art machining centres. Typically the production process and lead times can (and have) been reduced by a factor of 4 when New Technology is implemented together with Lean/Six-Sigma. The improvements enable the development of new products at an increased pace with resulting increased revenues and margins per component.
Automated Line
Lead time reduction