Lean Manufacturing

Project Detail

Client: A manufacturer of checks

Business Area: Multiple manufacturing plants

Opportunity: Streamline the manufacturing process to increase plant capacity in anticipation of a merger

Approach: Deployed workplace organization (5S) and Lean cells to improve machine uptime, reduce the space footprint, and remove non-value-added motion


  • Deployed “5S” workplace organization across 9 plants; created one Lean “pilot cell” and expanded to other plants
  • $1.7 million of plant capacity improvement (cost avoidance)
  • 30% reduction in manufacturing space usage with Lean cells
  • Post-acquisition, closed 2 plants to harvest capacity gains

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