Illustrations of rapid lean transformation

1. Ed Cucinelli – Operations Executive
Lean Transformation – Tallahassee, FL
Feb-2012 May-2012 Kaizen #1: Mainline Assembly Mar-2012
Key Goal: Improve Delivery to Customer
Measure Before After Improved
Process Time (hours) 192 9.8 95%
Floor Space (sqft) 19,701 14,272 25%
Travel (feet) 543 162 70%
WIP (# housings) 213 20 91%
Project Overview Time 4 Weeks
Motor insertion to packing Cost $15k
Kaizen #4 : Shaft Manufacturing Aug-2013
Key Goal: Improve consistency in throughput and yield
Measure Before After Improved
Process Time (hours) 120 - 160 7 95%
Floor Space (sqft) 2,045 1,500 27%
Travel (feet) 679 90 87%
WIP (# pieces) 215 21 90%
Project Overview Time 2 Weeks
Bearing machining to shaft balance Cost $30k

2. Ed Cucinelli – Operations Executive
Lean Transformation – Orlando, FL
Mar-1999 Jun-1999 Dec-1999
Year 1 versus Year 2
Inventory
- Reduced inventory by 50%
- No FG : 100% make-to-order
Productivity
- Process time : 2 days to 15 mins
- Lead time : 8 weeks to 2 weeks
- Equipment :13 benches to 5
Customer
- Delivery : 70% to 95% on-time
- Quality : 100% test all product
Financial
- Profitability : increased 50%
- Opened 41% of mfg space