Cross-Functional Kaizens & Key Talent Solutions Catalyzed Lean Transformation For Industrial Manufacturer

Lean Focus Industrial Business Transformation

For more than a century, the company had been a leader in providing industrial safety solutions. As it grew from a small company to a large corporation, however, it became difficult for the company to maintain a culture of continuous improvement, lean manufacturing, and waste reduction.

The company’s CEO reached out to Lean Focus because they wanted their company to see exactly what a Lean Transformation could do for the company in terms of driving results in productivity, setup times, and inventory reduction.

Lean Focus conducted cross-functional Kaizen events and bootcamps to create model-cells in the factory. Lean Focus introduced the concept of looking at the key metrics needed to make improvements on a daily, weekly, and monthly basis. Lean Focus also concentrated on how to collect and analyze data to determine where the company should put its resources and prioritize their day-to-day work. Topics included setup reduction, daily management, problem-solving, and strategy deployment. Additionally, Lean Focus helped accelerate the company’s Lean Transformation by sourcing them a proven CI leader.

Single-Minute Exchange of Dies (SMED) is a system the company uses for dramatically reducing the time it takes to complete equipment changeovers. After conducting a SMED Kaizen event, the company was able to complete it in less than half the time. The company also had more than 177,000 works in process, and we were able to reduce that to 60,000. We were also able to improve the company’s 6S score (how organized a particular area is) from 25% to 90%.

Key Outcomes

3x 6S Score
66% Work-in-Process Improvement
53% SMED Changeover Time Reduction