This document outlines a strategic integration project for a manufacturing plant experiencing various business problems including poor customer service, high costs, and quality issues. An evaluation found issues with operations, bonding with customers, product offerings, quality control, human resources, and technology. Projects were proposed to address these areas, including improving the plant layout, implementing lean processes, standardizing work, upgrading energy systems, enhancing quality control, providing training, and establishing processes to enable future automation. The long term plan was to solve all problems to leverage knowledge for automating the plant. Updates provided results from implementing lean process design, quality systems, energy reduction projects, and using statistical analysis to track cost improvements and effects of continuous improvement.

1. Strategic Integration
Business Case
Cultural Evaluation
Project Plan
Policy Deployment Matrix
Results

2. Strategic Integration Project
Business Problems
Poor Delivery and Customer Service
Cost Competiveness
Scrap at 5% of sales
Plant losing significant cash and income

3. Company Culture Evaluation
Operations
No lean work
Labor underutilized
Bottleneck not managed
High energy cost electricity used for
wash water $1,100,000 energy bill
No significant safety process
Bonding
Weekly customer rejects
On time delivery is dismal
Strained personal relationships,
customer can go elsewhere for parts.
Product Offering
New product introduced with
significant quality problems.
Quality
$1,000,000 in scrap
No process controls
Human Resources
No training of senior or middle
managers.
Direct labor are basically
considered machine loaders
Technology
Sister plant making similar product
are automated to reduce labor cost.

4. Projects to move from A to B
Operations
Plant layout improvement to
improve bottleneck
Standard work project to improve
labor utilization.
Standard work project to improve
labor utilization in assembly/honing etc.
Do significant cap ex energy project
to convert electric heat to gas heat.
Bonding
Create written corrective actions for
all customer rejects to demonstrate we
have controls on the problems.
Make presentation on bottleneck
improvements and lean improvements.
.
Product Offering
Suggest design changes in new
product.
Quality
Perform Black Belt level project
and 4 Green Belt projects.
Create controls in plating and
machining.
Human Resources
Eliminate some managers.
Training for managers, ISO,
Greenbelt, Lean, Safety,
Train direct labor in SPC, Process
control, and lean implementation
Technology
Create robust processes ready for
automation.

5. Strategic Integration Project
Long term plan: Solve all of the problems and leverage the
knowledge to automate the plant.

7. Project Performance
All projects at edwardhalljones.com
Lean Process Design
Scorecard A3: 2 stroke machining
Plant layout Project
Resilient Quality Systems Design
Case Study: Improve Process Control, Implement SPC, Resilient Corrective
Actions----- summary of actual work performed
Six Sigma Projects
Broken Fins, Perpendicularity of bore, Compression Volume
Energy Systems
Case Study: Reduce Process Energy

8. Use Minitab to track cost improvement
Note reduction in cost variation as lean is implemented

9. Determine the supply curve
Demonstrates the effectiveness of continuous improvement and the effects
of volume on price.