We have saved important portions of defective raw material through particular studies, finding and eliminating erroneous operations. Savings in percentages were around 30% on production lines and up to an estimated of $500,000.oo/year*
Some problems may annoy us most of the time, and these could be so distracting that the really important issues could be shaded by these less important and pass at the front of our eyes without noticing them.
Once we discovered that we were called to solve a very annoying problem at less than 1% of the total cost* and a wide range of issues were being shaded by this small but very annoying problem.
We proposed the reviewing of the operations management system in order to start measuring as much as possible towards finding where the true problems are.
On a preliminary study delivered in 4 months, including only the planning phase, we proposed 21 actions or countermeasures for the operations improvement on a Freight transportation company; these should save about 30%* of the actual operating cost.
Auto parts manufacturers have been in the business for several decades and competition for a market share is part of the day to day. The TOYOTA(r) Production System has revolutionized the industry and our experience is based on this system. Machine’s quick set up from hours to minutes, factories internal redistribution for a 66%* total area reduction, lowering machinery breakdown time based on maintenance programs design and implementation; they are some of the key strategies that we have included in our asset and which we have used in conjunction with our customers.
Balancing production lines will save money to the company. We have prevented high expenditures in packaging manufacturing facilities through the production line/cell optimum design. The needed personnel was reduced to 66%*, work in process (WIP - inventory) reduced to the minimum possible, and delivery time was reduced to 20%* of the one offered on the original design.
Following the general KISS principle, which stands for Keep It Smart and Simple, a test phase for a grading system was designed and implemented during two semesters bringing back the benefit to allow ONE grader assistant to revisit and grade up to around 150 assignments* every 20 hours/week
One of the achievements that make us proud is the experience of a department total reengineering in a bank. After 23 months of hard work these were the main achievements:
- 66% of the workforce* was reassigned to other activities in other departments
- Bureaucracy was minimized after restructuring some customer oriented procedures and the response time to costumer was reduced from 15 days to 15 minutes*, THIS IS MORE THAN 99% IN TIME REDUCED, THAT WAS PASSED INTO COSTUMER SATISFACTION.
* results may vary depending upon specific variables inherent to every situation