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Transformation through Lean Principles: A Success Story in Improving Manufacturing Processes

Explore how a company benefitted from Lean Manufacturing sponsored by ONR, BIW, MEP, achieving significant cost reductions and improved productivity through training grants and continuous improvement efforts.

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Transformation through Lean Principles: A Success Story in Improving Manufacturing Processes

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  1. Kerstin Forrester, President May 25, 2004

  2. IMPROVEMENT EFFORTS • Pathways participants – Lean Manufacturing • Sponsored by ONR, BIW, MEP • Assessed all facets of company • Order processing • Customer service • Manufacturing Processes • Received training grant from ONR • Massachusetts Workforce Training Grant

  3. MEP Training • Lean Principles • Value Stream Mapping • 5-S • Set-up reduction (SMED) • Continuous Improvement • Team Building • QMS => ISO compliant

  4. Cost Reductions • Material costs reduced by 28% • Rejections & reworks reduced 5% • Productivity improved 60% vs. early 1999 • Break-even sales reduced by 25%

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