Helping a Specialty Materials Producer Apply FMEA And Preventative Maintenance To Reduce Scrap

Second of two Kaizen events After DPA helped its employee team successfully complete a first scrap reduction kaizen event for its top product line, the CEO of a wire, cables and connectivity product company again called upon our consulting team … [Read more...]

Helping a Specialty Materials Producer Embrace PDCA Culture

DPA recently worked with a manufacturer of wire, cables and connectivity products to reduce scrap at one of their factories. The kaizen team worked with DPA senior consultant Nicole Snurkowski to reduce scrap on a wire product line that represented … [Read more...]

Precision Components Manufacturer Shaves 56% Off Machine Set-up Time

An established, family-owned manufacturer of precision engine parts for aviation clients needed to boost productivity on the company’s turning machines. Improvement methods, which would focus on set-up time reduction, had to maintain exact tolerances … [Read more...]

How to get OCM Right: Questions and Steps to Lasting Change

By Jon Thorne, Daniel Penn Associates Is your organization contemplating major changes in structure, operations, business practices? Unless the change is something minor, like a process adjustment or a new role, making lasting change through an … [Read more...]

How to Not Sabotage Production

Free Manufacturing Self-Assessment How are you tracking your facility's production availability, throughput and quality? How much time are you spending on RCM, PdM, TPM, inventory control? What's the plan for keeping everyone up to speed and … [Read more...]

A New Look at In-sourcing and Cell Layout Boosts this Manufacturer’s Capacity by 107%

Situation A leading supplier of forgings to Tier I and II aerospace, defense and automotive companies won a significant contract. As the company ramped up a new production process under the contract, they discovered their outsourcing operations … [Read more...]

Are Cobots Part of Your Plant’s Future?

How to begin with Lean Robotics “You’re still gonna have to have the people here.  Somebody’s still gotta man that machine that’s supposed to be able to do everything. And tell us when that machine doesn’t want to work the way it’s supposed to.” … [Read more...]

How to Make Your Plant Reliable

Five basics to make your Lean and RCM programs play well together. The bottom line: Lean relies on takt time as the cadence for producing to meet customer demand. Takt time assumes that critical process equipment will be reliable (i.e., … [Read more...]

How to Succeed at a Gemba Walk Using the 3Gen Principle

Regardless of your industry, you may have observed (or actively participated in) the 3Gen principle, commonly known as a Gemba Walk. Do you and your team know how to truly prepare yourself for and succeed with Gemba Walks? First, a little … [Read more...]

The Other Approach to Lean

Product Quantity Analysis, the Process Matrix and the Spaghetti Chart Total Productive Maintenance, Six Sigma, Set-up Reduction or 5S methods may be used either separately or together to help a facility’s team define the best path to a lean goal. … [Read more...]