Increasing operating income and efficiencies for a manufacturer

Enabling efficient high speed manufacturing.

This client is a manufacturer of injection molded products, with operations in Canada and the US. 

The issues the company faced were filling orders on-time and fully, cutting overtime, and CAPEX deficiencies.  A Kaizen event was implemented and identified issues, which included machine speeds, up-time, and two under-performing plants.  

Implementation of Lean Six Sigma measured results versus newly created standards, which held teams accountable and recognized team results.  Other implementations included Gemba Walks, Single Minute Exchange of Die (SMED), maintenance and scheduled meetings, standard hours for work orders, and shift hand off meetings.

The result was an improvement of $6.7 million, decreasing overtime expenses by 81%, increasing tech productivity by 224%, increasing incremental margins by $2.4 million, and reducing defects by 2%.  

Some client engagements shown may have been executed by NMS consultants at prior firms.