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Our
Approach
1)
No Cost No Obligation
Factory Evaluation
Consists of a short questionnaire and a tour of your facility*.
About a week later you will receive an evaluation of your
factory including places where you could reduce your manufacturing
costs.
Click
to request an appointment
2)
Identify the “Bottlenecks” Upon
hiring us, the first thing we do is look for the bottlenecks.
We conduct time
studies on each operation (as required) to get the average process
time for a typical product.
We
subscribe to the Theory
of Constraints which says that one or two bottlenecks
limit the number of products you can ship to your customers per
day. Since
the bottlenecks are usually not the first or last operation, any
operations that are producing faster than the bottlenecks are just
creating excess work in process (WIP).
3)
Client Decision Now
that the bottlenecks are identified the client chooses between the
following two options:
-
Use
our Process Analysis service on
the bottlenecks to look for ways to increase production.
This option is less costly, and is less disruptive than
option 2.
-
We
will put a plan together to tie all the operations to the
bottleneck operations and balance the entire manufacturing
process.
This option takes more time to complete but will
typically cut lead time in half and significantly reduce labor
and manufacturing costs.
Both
options are guaranteed
to pay back in 6 months.
4)
Change The
new methods or equipment is implemented with the least disruption
to the production of product as possible.
“Nobody
likes change except a wet baby”.
We are sensitive to the fact that people are
uncomfortable with change.
Once the plan to implement new methods is finalized or new
materials and equipment have been procured, we explain to
employees the goals of the change.
By explaining up front what we are doing, why we are doing
it and the expected outcome, it makes people more accepting of the
change.
5)
Training and documentation
All personnel that are responsible for the process are trained.
An instruction manual is also provided.
6)
Evaluation of the improved process Our
job is not complete until we have verified that the goals of the
project have been achieved and the customer is satisfied with the
results.
Follow up visits are scheduled at 1 month and 6 months or
as needed.
*All
information will be considered confidential and will not be shared
with anyone.
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