Projects
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
Results:
- 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
