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With rising manufacturing costs and inefficiencies in operations, Production Technologies was fundamentally rethinking its operations model, including front office processes. One area of great concern was the Document Control Routing system which was currently taking more than fifteen days to process.
To help Production Technologies improve operational effectiveness, Manex developed a comprehensive Lean program. The program was comprised of a one-week in-depth Office Lean and Master Scheduling event covering 5S methods in 8 targeted areas. Two instrumental tools developed within the session were a Value Stream Map which identified the bottlenecks in the ISO Document Control Routing, and a Master Scheduling Board with key performance indicators (KPIs) to help the company stay focused on goals and results.
Through the implementation of this comprehensive Lean program, Production Technologies was able to generate a $47,000/year cost savings with a newly re-energized, empowered team. Lead time in the ISO Document Control Routing process was reduced significantly by 86%. Efficiencies were also gained in the front office by re-arranging the lobby, work centers, and copy center. A better process for managing office equipment was also implemented using a Total Productive Maintenance methodology.