Today’s manufacturing companies can no longer rely on slow, wasteful manufacturing processes if they want to stay relevant in the 21st century global economy. In the face of unprecedented competitive and cost pressures, more companies are turning to LEAN Process Improvement Manufacturing practices to realize quick, dramatic:
• Reductions in waste
• Improvements in productivity
• Reduced lead time for orders
• Improved quality
• Reduced cost
• Reduced inventory
• Better floor-space utilization and asset utilization
• Improved “cash to cash” time
What Is Lean Manufacturing?
The LEAN methodology is based on manufacturing principles that were first developed and implemented in Japan by auto manufacturer Toyota. It provides a systematic approach to waste reduction in the manufacturing process. The lean philosophy focuses on identifying process steps that provide value to the customers and eliminating everything else. A fundamental Lean principle is finding ways to do more with less. The development of a targeted LEAN manufacturing strategy requires a careful evaluation and implementation of the following:
- Identifying the specific customer issues the manufacturing organization will resolve to help it achieve its own objectives
- Assessing each major value stream to ensure each process step is flexible, valuable, adequate, capable and available
- Ensuring that every critical manufacturing process is overseen by an individual who is charged with the responsibility of constantly evaluating the specific value stream regarding the LEAN process and business purpose
Local Lean Manufacturing Success Stories:
Industry |
Benefits |
| Light Assembly | Improved on-time delivery from 60% to above 90% |
| Metal Fabrication | Reduced set-up time on a bottleneck machine from 55 minutes to 19 minutes |
| Food Processing | Reduced set-up time from 38 minutes with one person to 9 minutes with 2 people |
| Wood Manufacturing | Reduced WIP $750,000 and increased productivity 23% |
| Heavy Manufacturing | Reduced month-end closing process from 7 days to less than 3 days |
| Heavy Manufacturing | Reduced incoming freight costs by over $300,000 Distribution Improved throughput in shipment packing by 24% |
| Plastic Fabrication | Reduced product waste $90,000 and $50,000 electric usage |
| Light Assembly | Reduced lead time from 3 months to 2 weeks Metal Fabrication Reduced order backlog from 4 months to 2 weeks. |
| Wood Manufacturing | Increased productivity from 4 units per day to 7 units per day with no additional manpower |
Participate in Advanced lean Process Improvement Training at Our LEAN Showcase
NEPIRC offers advanced process improvement training to PA manufacturing organizations. Our York, PA headquarters houses the LEAN Showcase, a state-of-the-art, fully functioning manufacturing facility where you and your team can get hands-on lean training that will streamline and simplify your processes and increase your operating efficiency. With our process improvement training, you will learn how to minimize common sources of waste that prevent many organizations from reaching their productivity and profitability objectives.
NEPIRC Can Also Help You Attain LEAN Certification
We offer a wide variety of LEAN training courses, many of which lead to LEAN certification. Certification validates your expertise and ensures the best results when applying the LEAN fundamentals in your manufacturing operation. We offer basic and advanced certification training programs in all aspects of the lean methodology — including LEAN accounting training, value stream mapping, office/process management, team facilitation and much more.
Check Our LEAN Manufacturing Success Stories
Our process improvement training and other lean-related services have helped numerous PA companies in industries such as Light Assembly, Heavy Manufacturing, Plastic Fabrication and Food Processing streamline their manufacturing processes and reduce waste. Take a look at our local LEAN Manufacturing Success Stories:
Learn More About Our PA lean Process Improvement Training Services
Discover the many ways LEAN can revolutionize your manufacturing operation and give you a competitive edge in the marketplace. For more information about our LEAN services, Call NEPIRC First at 717-843-5054 or contact Leigh Ann Wilson at wilsonla@nepirc.org.
NEPIRC provides Lean Manufacturing Process Improvement programs & services to manufacturers located in the following Pennsylvania counties: York, Lancaster, Lebanon, Dauphin, Perry, Cumberland, Adams, Franklin and Fulton.