Case Studies

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Manufacturing Line Optimization

Objective: To optimize the frame production line, improve throughput, and reduce labor costs.

Approach:

Conducted time studies and identified inefficiencies in the batch production process.
Converted the assembly station to a one-piece flow process.
Implemented ergonomic changes to reduce fatigue and improve tool accessibility.

Results:

Increased production throughput from 50-55 units per 10-hour shift to 65-70 units.
Reduced labor by reallocating 4 operators, saving approximately $200,000 annually.
Reduced service orders from 60 per month to 10, improving product quality.
Yearly monetary impact: Additional revenue of $550,000 to $825,000 due to improved throughput.

Stop System Implementation

Objective: To reduce errors in cutting materials and improve product quality on the frame production line

Approach:

Introduced a $25,000 automatic stop system for the saw station, integrating with the network to automate cut lists.
Eliminated manual calculations by operators, reducing the potential for error.

Results:

Reduced service orders from 30 to nearly 0 per month, saving $55,000 monthly in rework.
Decreased recuts from 60 to 20-30 per month.
Yearly savings: Approx. $1,320,000 in material, labor, and rework costs.

Value Stream Mapping

Objective: To create a value stream map (VSM) for the frames department to improve production planning and efficiency.

Approach:

Conducted time studies for each task in the department.
Developed a detailed VSM to track lead times, task duration, and overall process flow.
Used the VSM to help managers and the scheduling team optimize production and prevent bottlenecks.

Results:

Improved scheduling efficiency and balanced the workload across shifts.
Real-time production efficiency tracking allowed managers to respond quickly to inefficiencies.
Long-term operational improvements in workflow consistency.

Hydraulic Product Development

Objective: To develop and launch a range of hydraulic products, including control valves, diverter valves, cylinders and hydraulic kits.

Approach:

Conducted market research and collaborated with overseas manufacturers to design hydraulic product.
Developed plug-and-play hydraulic kits for DIY customers.
Established a process to test & validate hydraulics components.

Results:

Partnered with the supply chain team to introduce new vendors, ensuring their products aligned with the company’s lineup and maintaining quality standards, resulting in the successful introduction of a new product, the hydraulic cylinder.
Developed a comprehensive testing and validation process for incoming hydraulic components, establishing benchmark standards for valves that improved quality control and ensured all products met company performance requirements.
NPD delivered weekly sales of $40K, representing 20% of the company's total revenue within the first two years, highlighting the product's pivotal role in the company’s portfolio.

Automotive Suspension Product Development

Objective: To develop and launch automotive suspension products, including eccentric lockout kits, adjustable end links, and coil overs.

Approach:

Conducted market research to identify gaps in the automotive suspension market.
Designed and developed multiple suspension components tailored to specific vehicle models.
Implemented rigorous testing protocols to ensure all new components met industry standards and provided superior performance compared to existing products.

Results:

Identified three key gaps in the market, leading to a 25% increase in product offerings.
Successfully launched five new suspension components, resulting in a 30% boost in sales within the first year.
Enhanced customer satisfaction scores by 15%, driven by improved vehicle handling and comfort.

ISO A9100:2015 AS9100D Certification

Objective: To implement ISO A9100:2015 AS9100D certification on the manufacturing line

Approach:

Conducted a thorough assessment of the existing quality management system to identify deficiencies and areas for improvement.
Established a schedule for regular internal audits to monitor compliance, identify non-conformities, and drive continuous improvement.
Developed key performance indicators (KPIs) to measure the effectiveness of quality initiatives and track progress over time.

Results:

Achieved a 60% decrease in rework, significantly enhancing productivity.
Reduced customer service tickets by 50%, reflecting improved product quality and customer satisfaction.
Improved the quality of documentation by 70%, facilitating better compliance and traceability.
Realized annual savings of $1,456,000 from reduced rework and opportunity costs, alongside a 50% increase in operational efficiency.
Return on investment significantly exceeded the initial $150,000 investment, demonstrating the effectiveness and value of the quality management enhancements.

Vinyl Frames Line Optimization

Objective: To optimize the vinyl frames manufacturing line and reduce inefficiencies in the department

Approach:

Introduced an automatic stop system for the saw and converted the line to a one-piece flow process.
Implemented an automatic stationary nail fin router, reducing cycle time and eliminating the need for additional operators

Results:

Reduced service orders and recuts, leading to almost zero monthly reworks.
Saved approximately $150,000 in labor costs by reallocating three operators.
Improved throughput from 30 units to 42 units per 10-hour shift.

Infeed Table Development

Objective: The objective is to design a cost-effective table that facilitates comprehensive quality control, ensuring product functionality is thoroughly verified prior to packaging.

Approach:

Enhance and optimize the design concept to ensure both functionality and overall effectiveness.
Investigate and implement innovative techniques for simulating door functionality to ensure precise testing of opening and closing mechanisms.
Establish a comprehensive checklist for product performance verification, with a focus on smooth operation and precise alignment during testing.

Results:

Finalized the infeed table design, reducing the initial cost from $95,000 to $17,000 through multiple redesigns, while cutting rework and service orders by 50% due to improved mock-up implementation.
Boosted production throughput by 20%, resulting in a 15% increase in annual savings.
Prioritized product quality and customer satisfaction by exceeding high standards, while reducing operator downtime and streamlining workflows, particularly during packaging, to enhance overall productivity.

Hinged Door Production Line Optimization

Objective: The objective is to thoroughly optimize the hinged door production line by identifying and addressing inefficiencies, thereby enhancing overall operational efficiency and ensuring a smoother workflow throughout the manufacturing process.

Approach:

Conducted time studies across production stations (saw, CNC, hardware, assembly, mocking, and glazing) to identify inefficiencies and bottlenecks, implementing solutions to streamline the process and enhance productivity.
Transitioned to a one-piece flow production method by eliminating WIP racks and reorganizing tables, while redesigning workstations to keep tools within reach, reducing travel time and adding tool stations to further improve workflow efficiency.
Established clear communication with both shifts regarding process changes, fostering collaboration and idea-sharing to boost floor productivity, and designated specific shifts for different door types to increase overall throughput.

Results:

Achieved an additional 10-15 total scans for 4 different product series per 8-hour production shift, reducing operator downtime and improving workflow efficiency.
Boosted annual revenue from $5.09 million to $7.64 million by optimizing production throughput across both door types over a 52-week period.
Reduced part mix-ups and backorders, ensuring timely delivery and meeting customer demand more effectively.

CNC Program and Project Optimization

Objective: The objective is to systematically optimize existing and new programs by analyzing workflows and implementing enhancements, alongside designing specialized jigs to improve accuracy and efficiency in the production line. This strategy seeks to reduce cycle times, minimize errors, and enhance overall productivity and product quality.

Approach:

Analyzed current CNC program operations and observed production workers to understand their processes and identify improvement opportunities.
Engaged with production workers to streamline tasks and collaborated with manufacturing engineers to optimize processes and share innovative ideas.
Enhanced the existing CNC program for greater efficiency, applied these improvements to new programs, and developed a simple, user-friendly jig design for optimized processing..

Results:

Current and new programs operate more quickly and efficiently, enhancing overall performance and productivity while minimizing downtime and resource usage, and by incorporating jigs that simplify tasks for production workers, we achieve a 10% increase in production throughput.
Improved process accuracy ensures higher product quality, meeting customer expectations and enhancing overall satisfaction.
Active engagement with co-workers fosters better communication and teamwork, boosting morale and driving innovation and problem-solving across the workplace.