Work Examples
Safety System Deployment
A manufacturing and distribution organization had experienced a great deal of growth and safety was lacking. We were asked to support them by conducting a safety assessment of their systems. In response to our findings, we developed a "Train the Trainer" plan to train leaders of sites in standard safety protocol. We deployed a Behavior Based Safety System and trained the teams in effective problem solving and Job Safety Analysis so that the most critical risks were identified and the teams were trained properly to reduce risks from those jobs. 5S training and standards were created and a "Trained the Trainer" plan was used for deployment.
Tiered Operating System to Manage for Daily Improvement
An industrial restoration products company was looking to "reengage" a smaller division of one of its portfolio companies. Through our partnership, we developed training and executed it across all their operating shifts with all associates. We partnered with key leadership and deployed Tier One (Manufacturing Cell level), Tier Two (Site Operating Level), and Tier Three (Pareto "Biggest Miss" Problem Solving Review) review structure. As part of these efforts, $480K of savings was achieved at one site within six months. Deployment followed at the other sites in the division.
Line Balancing and Material Flow - Product Focused Cell
A key assembly process in a heavy duty electrical component unionized plant was becoming a problem for plant financials and customer satisfaction. We developed a concept for this area using product focused cells with improved material flow for raw material part presentation to line side. New work stations were procured and ergonomic analysis was completed. Three product segmented cells replaced the old existing work lines that had been used. A system for a timed material replenishment was developed to reduce the amount of resources needed to support the cell. Once the project was fully implemented, the plant was able to eliminate OT and move resources to a new manufacturing product line. This generated $547K of savings for the site.
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Phone 812-371-1993