CASE STUDIES

  • Yamazumi (work balancing) highlights 12% throughput improvement

    Results: A disc brake pad manufacturing business questioned its 'conventional wisdom' of assigning operators to semi-automatic presses.  Working with press operators, CLS analysed press loading, cycling and unloading cycle times over a range of press cure times to identify the opportunity for a 12% increase in production throughput.  During this…...

    Read More...

  • Value Stream Mapping (VSM) identifies $170k in process waste

    Results: In light of moving some of its production offshore, an SME rubber products manufacturer questioned the entire business process for one of its product lines.  CLS generated Value Stream Maps (VSMs) for engineer-to-warehouse processes, challenging the status quo and management 'thought inertia' at all process steps to identify sixteen projects/studies,…...

    Read More...

  • Reducing change over time resulted in savings of over £2M

    Results: The outcome from the SMED activity has been to reduce a change- over time from 45 minutes down to 6 minutes.  This meant the change over can be accommodated in the scheduled 10 minute operator break, and has eliminated 27 hours of stoppage per year. This equates to sustainable…...

    Read More...

  • Successful Die Change Quality (DCQ)

    What we achieved: Prior to the activity the data showed for all parts produced within the period, average DCQ of 91%, with 25% of parts exceeding 100% Following the CLS lead activity, average DCQ of 96%, with 39% of parts exceeding 100% Monetary value: A sustainable saving of £460,000 per…...

    Read More...

  • Product Improvement Programme in Multinational Manufacturing Company

    Results: The six work groups (a total of 141 associates) raised 332 Kaizens during the activities, with 95% requiring minimal cost investment, and 82% implemented.​ The following were also achieved,​ Reduction in number of Processes from 47 to 39.​ 27 Associates and 3 Supervisors re-allocated to new manufacturing area saving the…...

    Read More...

  • Quick Change Over resulted in $145,000 cost avoidance

    Results: A repetition engineering company determined that reducing change over time on its broad mix of manual and CNC machines was necessary in order to remain competitive. Complete Lean Solutions Pty Ltd worked with a cross-functional team of operators and support staff to train, measure, apply and standardise Quick Change…...

    Read More...