• 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
   - $2.9 million in hard cost savings; $3.3 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

• Client: A manufacturer of checks

• Business Area: Multiple manufacturing plants

• Opportunity: Reduce the rare but critical rate of “non-public information”
   errors (NPIs) caused by “flipped and folded sheets” that occur in the
   printing process

• Approach: Initial error rate (across all plants) averaged four per month;
   project identified potential causes and used a Design of Experiments (DOE)
   approach to confirm root causes, then designed preventative actions

• Results:
   - Designed and implemented solutions in both machine setup and
     operational procedures (and accountabilities)
   - Reduced overall NPI errors for the company by 75%
   - Reduced NPI errors for that defect type to zero