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"Providing Solutions For Creating Customer Value" We help organizations focus on creating customer value and eliminating waste to achieve gains, ranging from 40% to 80%, in quality, productivity, cost reduction and customer response time.
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Companies hire us because of our experience, knowledge and passion for improving process performance
Case Histories ISO 9000 Projects
Customer: Design-build Construction Company Sector: Construction Scope: ISO 9001:2000 implementation Interventions: Policy and procedure preparation Results
achieved: Client
implemented the procedures resulting improved operations and a reduction in
defective work. Customer: Display and Exhibit Company Sector: Manufacturing Scope: Transition from ISO 9001:1994 to ISO 9001:2000 Interventions: Developed policy manual and revised procedures to meet the requirements of ISO 9001:2000. Trained internal auditors and conducted internal audits of the quality system. Results achieved: Client passed his surveillance and transition audit on the first try without any non-conformances. Customer: Carbide Cutting Tool Manufacturer Sector: Manufacturing Scope: Implement ISO 9001:2008 Interventions: Developed policy manual, procedures, work instructions, and forms to meet the requirements of ISO 9001:2008. Trained internal auditors and conducted internal audits of the quality system. Assisted in applying for State of Illinois grant to help fund the project. Results achieved: Client passed certification audit with only three minor non-conformances, which were closed out before the audit was completed. Client also received State funding covering 50% of the cost of employee training. Process Improvement Customer: Major Health Care Company Sector: Pharmaceuticals Scope: Provided Team Problem solving training for one division and process mapping for Mail and Package delivery group. Interventions: Problem solving tools and methodology, Current state and Future state functional and cross functional mapping, value-add analysis. Results achieved:
Customer: Middle Market Tier 1 Automotive Supplier Sector: Manufacturing Scope: Business Process improvement/Cycle Time Reduction Interventions: Business process mapping and team problem solving Results achieved: Assisted a client team of engineers and sales people using business process mapping and cycle time reduction methodologies with mapping and redesigning of the engineering product development process reducing cycle time from 3 years to 18 months on first pass. Also slashed the product development cycle time of another division from 18 months to 6 months using the same tools and techniques. Customer: Construction Contractor Sector: Construction Scope: Business Process Mapping and Redesign Interventions: Process redesign/value add analysis Results
achieved: The
objective was to have all financial reports submitted to senior management
within 10 days after month end close. We worked with the client team to improve
the Accounts Receivables and financial reporting process. Mapped and redesigned
the AR process to reduce total delays of 14 days. We also eliminated 18
non-value-added steps in the first future state of the entire financial
reporting process reducing the reporting cycle from 24 work days to 10 work
days. Performance metrics were established for Accounts Payables, Accounts
Receivable, and the payroll functions to ensure attainment of the 10 day
reporting cycle. Established a performance measurement board for AP, AR, and
Payroll to track productivity, flow time, and first time through quality. The
performance measurement board was the first step in establishing a culture of
continuous improvement. Lean/Six Sigma Process Improvement Customer: Major Consumer Products Company Sector: Manufacturing Scope: Lean Manufacturing Assessment Interventions: Employee Lean Overview Training, Lean Business Simulation, Lean Assessment, Value Stream Mapping, value-add analysis, available time to uptime analysis, downtime analysis, changeover analysis, overall equipment effectiveness (OEE), customer demand analysis (takt time), and recommendations to achieve Future State. Results achieved: Client use the results of our analysis and recommendations to self-implement their Lean project. Customer: Middle Market Global Product Safety Organization Sector: Service Scope: Lean Assessment, training and implementation in the U.S., Europe, and China Interventions: Kaizen events, Value stream mapping, Root cause analysis, 5S, Kaizen team facilitation and Lean System for Managing engineering projects Results achieved: Europe Transaction Center Kaizen resulted in reducing lead time for preparing customer certification documents from 65 days to 10 days; Created Value Stream maps for North American, European, Asian Transaction Centers and Fire Safety Division. Identified kaizen activities to achieve the future state; Facilitated Lean System for Managing for five Conformity Assessment Sections in a $6 million division resulting in a 33% reduction in project WIP for one section and improved workflow; assisted lean change agent and 5S team to implement 5S in Canadian operation; Trained numerous employees in lean applications (takt time, root cause analysis, leveling, continuous flow, and first pass yield). Reduced order lead time from 7 days to 2 days for alarm protection group. First quarter revenue following completion of project increased by 20% with gross margins of 40%. Customer: Middle Market Airline Caterer Sector: Food Service Scope: Lean Assessment Interventions: Value stream mapping and identification of capacity constraints. Results achieved: Facilitated current state and future state map preparation identifying performance gaps and barriers preventing the organization from increasing capacity, reducing costs, and improving customer service. Customer: Middle Market Food Manufacturer Sector: Food Processing Scope: Lean Six Sigma Assessment Interventions: Cost of poor quality assessment and capacity analysis. Results achieved: Identified over $5 million in scrap and rework costs and other non-valued-added wastes (excess motion, transportation, defects, etc.) contributing to capacity loss. Identified Lean/ Six Sigma projects and devised a plan to increase capacity 10% with no additional capital expenditures. Customer: Active Pharmaceutical Ingredient Manufacturer Sector: Drug Manufacturing Scope: Reduce changeover times to provide additional capacity for a high volume product Interventions: Quick Changeover Kaizen Results achieved: Kaizen team reduced the changeover for key API from 11 days to 3 days. Organization Development Customer: Middle Market Financial Institution Sector: Banking Scope: Custom Training Design Interventions: Organization Facilitation Results achieved: The client's objective was to design training for a desktop of financial tools for Portfolio managers. Worked with the IT group to design the facilitator's manual, participant guide, and a computer-based module for the Portfolio managers. Customer: Small Fastener Manufacturer Sector: Manufacturing Scope: Define Employee Knowledge, Skills, Abilities and Competencies Interventions: Facilitation Results achieved: Defined the competencies the company needed to double the business in 3 years. Identified current employees that would be able to develop the competencies. Consulted with management to develop a process for assessing employees using new competencies. Used the competencies matrix for recruitment, training and development, managing performance and to develop a succession plan. Partial Client List: Abbott Laboratories, Ark-Les - U.S. Controls Division, Bar-S Foods, Caremark Rx, Flying Food Group, Great Lakes Synergy Corporation, Horning Wire, International Decorators, Inc, Medline Industries, Nimlok Company, Nordenia USA, Noramco, S.C. Johnson, Stuckey Construction Company, Inc., Takeda Pharmaceuticals NA, Underwriters Laboratories, Wilton Tool
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Quantum Associates, Inc
