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Senco’s Lean Transformation

Senco’s Lean Transformation. Dewey Warden. Senco’s Lean Transformation. Senco began implementing Lean operations in 1993 with Tool Manufacturing Toyota personnel worked with Senco in 1994 for nine months to teach us the concepts. Senco’s Lean Transformation.

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Senco’s Lean Transformation

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  1. Senco’s Lean Transformation Dewey Warden

  2. Senco’s Lean Transformation • Senco began implementing Lean operations in 1993 with Tool Manufacturing • Toyota personnel worked with Senco in 1994 for nine months to teach us the concepts

  3. Senco’s Lean Transformation • By 1995 for tool manufacturing we had implemented a Kanban pull system, cellular assembly, change over time reduction, and continuous improvement on the 7 wastes (overproduction, excess inventory, excessive processing, excessive conveyance, defects, waiting, and excessive motion), and had 400 tool manufacturing employees trained in Lean.

  4. Senco’s Lean Transformation • Productivity increased from from 3.5 to 6 tools per man hour • Changeover time for tool cells dropped from 40 to 5 minutes • From 4 months to 8 days of finished goods tool inventory • Fastener manufacturing rate of 4.6 defects per million opportunities • Tripled cash flow, reduced fixed overhead by 28% & WIP by $MM’s • Next challenge is to consolidate Cincinnati Tool and Fastener operations

  5. Senco’s Lean Transformation • Senco’s old information/material flow • Senco’s new information/material flow

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