Case Study Examples

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Break Through Kaizen - 1st Tier Automotive

Rapid Improvement Workshop to relocate production line 

  • 30% less space required
  • 70% less work in process
  • 62% less distance travelled
  • 40% lead time reduction
  • 34% increase in productivity

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Site Transformation - Automotive

  • Strategy Deployment Workshop
  • Value Streams Identified
  • 15 rapid improvement workshops completed
  • Overall productivity increased by 20%
  • cost of inventory reduced by 64%
  • Cost of quality reduced by 18%
  • 22% positive impact to the bottom line

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Lead Time Reduction - Actuator Industry

  • Problem: Losing business due to lead times of more than 28 days.
  • Target : 5 day lead time
  • Solution: A series of workshops to reduce variation and increase flow
  • Lead time reduction of 82% achieving 5 day lead time
  • Reduced In Process Inventory by 80%
  • Increased productivity by 40%
  • New service level allowed company to increase prices


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Customer Complaints - Pharmaceuticals

Before:

  • 120 days to close complaint
  • After:
  • reduced handoff by 66%
  • standard team meeting developed
  • investigation and root cause process scripted into the work day
  • Visual tracking of complaints
  • average time to close complaint 4 days (95% reduction in response time)

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Break Through Kaizen - Power Generation

Situation:

  • Enclosure assembly identified as a bottleneck impacting final assembly process.

Target:

Balance enclosure assembly to final assembly Takt Time

Action:

  • Break Through Kaizen

Results:

  • reduced work content by 37%
  • reduced lead time by 83%
  • Enclosure assembly balanced to final assembly