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Our mission is to anticipate and meet the process improvement and training needs of our clients with integrity, creativity, and a passion for adding value.
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Case Histories ISO 9000 Interventions 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. Helped client apply for a State grant to 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 funding from the State covering 50% of the cost of employee training. 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 Manufacturer 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. 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: Working with a client team of engineers and sales people using business process mapping and cycle time reduction methodologies we mapped and redesigned 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 a sister division from 18 months to 6 months using the same tools and techniques. Customer: Construction Contractor Sector: Construction Scope: Business Process Mapping & Improvement 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 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) analysis, customer demand analysis (takt time), and recommendations to achieve Future State Results achieved: Client used the results of our analysis and recommendations and began self implementation of Kaizen events within two weeks following our assessment. 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, 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; Worked with 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 Processing Scope: Lean Assessment Interventions: Value stream mapping and problem identification Results achieved: Facilitated current state and future state value stream mapping of critical processes to identify process performance gaps and barriers preventing the organization from achieving its objectives of reducing costs and improving customer service. Devised an improvement plan to achieve future state. Customer: Middle Market Food Manufacturer Sector: Food Processing Scope: Lean Assessment Interventions: Cost of poor quality and Lean Process Improvement analysis to help improve capacity Results achieved: Identified over $ 5 million in scrap and rework costs and other non-value added wastes (excess motion, transportation, defects, etc.) contributing to losses in capacity. Devised a plan to increase capacity 10% with no additional investment in capital expenditures. Customer: Active Pharmaceutical Ingredient (API) Manufacturer Sector: Manufacturing Scope: Quick Changeover Kaizen Interventions: Training and facilitation of Kaizen team, Value Stream mapping, identification of internal and external changeover activities. Results achieved: Kaizen team reduced the changeover for a key API from 11 days to 3 days. Organization Development Customer: Middle Market Financial Institution Sector: Banking Scope: Organizational Development Interventions: Training Design Results
achieved: The
client’s objective was to design training for a desktop of financial tools for
Portfolio Managers. We worked with the IT group and financial managers to design
the facilitator manual, participant guide, and a computer based training module
for the Portfolio Managers. Customer: Small Fastener Company Sector: Manufacturing Scope: Organizational Development Interventions: Talent Management Results achieved:
Partial Client List: Ark-Les - U.S. Controls Division, Bar-S Foods, Caremark Rx, Horning Wire, International Decorators, Inc, Nordenia USA, Wilton Tool, S.C. Johnson, Great Lakes Synergy Corporation, Noramco, Medline Industries, Abbott Laboratories, Nimlok Company, Stuckey Construction Company, Inc., Underwriters Laboratories, Takeda Pharmaceuticals NA.
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Quantum Associates, Inc
