Leading manufacturer of precision flow meters and components for the aerospace, semiconductor and medical device industries.
MAX Machinery continues to focus on providing high quality solutions to its customers needs, and the management team is proactively pursuing ISO Certification to address client demand and competitive pressures in the marketplace. Manex was asked to develop a comprehensive review of the operations and develop and implement plans that would immediately improve the company’s operations and cost structure and prepare the company for ISO 9001:2008 certification.
Manex used a proven, tailored approach designed to maximize the program impact to MAX. The program consisted of a detailed process map of the operations from order entry through shipping with a roadmap for improvement.
Actual Activities included:
- Creation of current state process maps to understand the flow of products from order entry through shipping
- Implementation of proven Lean Manufacturing principles to reduce costs, reduce defects and improve plant profitability to the shop floor
- Implementation of two Kaizen Events along with Practical Problem Solving & Root Cause Correction Action (RCCA) training
- Application of 6-sigma DMAIC Process during the shop floor kaizen events
- Implementation of “train the trainer” concept on Lean Manufacturing Principles and for internal ISO 9001:2008 requirements
- Creation of the ISO 9001:2008 quality manual and supporting documentation in conjunction with MAX personnel
As a result of these continuous improvement activities, MAX dramatically increased production levels, reduced annual operating costs, improved quality and improved time to market. With improved operations flow and trained production team members, MAX is positioned to exceed its operational requirements and achieve ISO 9001:2008 certification.
Specific results include:
- 50% improvement in cycle time in the testing labs with $20K/year in cost savings
- 30% improvement in on-time-delivery
- 22% improvement in first-pass-yield
- 30% reduction in rework
- 35% reduction in ‘over-processing’ activities
- 40% reduction in front office cycle times identified
- Streamlined scheduling and improved quality
"Manex has been a tremendous partner helping us with our Lean transformation. With their in-depth expertise, on-site support, and commitment to results, they have been instrumental helping us not only achieve significant results to date, but also ensuring that we have the processes in place to sustain them in the future."
—Tommy Dockery
Western Region Manager, Del Monte Foods