Lean Production
Lean Enterprise 

Case Studies

Lean Pharmacovigilance

Improvement Initiatives

  • Pull Replenishment Systems | Kanbans
  • Schedule Optimization Programs
  • Vendor Managed Inventory Programs
  • Right First Time
  • Cellular Manufacturing
  • Business Process Redesign
  • Value Stream Mapping
  • Lean System for Managing | Change Management | Team Working | Team Building | Supervisory Management Training
  • Strategic Sourcing | Supplier Certification | Supplier Negotiation/Selections
  • SMED, 5S, OOE, Poka Yoke

Client Benefits Realized

  • Average 98% compliance, improvement in capacity by 105% and removal of all non value adding steps.
  • $10.4 M run rate reduction in operating expenses.
  • Inventory reduction of 75%.
  • Space reduction of 30-60%.
  • Adherence to schedule of 90-100%.
  • Improvement in on time delivery to 96%.
  • Reduced time to changeover from hours/days to minutes yielding additional capacity of 5-25%.
  • Improved safety by 50%.
  • Reduced scrap by 30-50%.
  • Improved quality by 30-50%
  • Set 100% achievable metrics through goal attainment.
  • Supplier partnerships yielding no loss in production due to shortages or poor quality.
  • Reduction in M/AA by 50-80% and hand-offs by 30-50%.
  • Decreased distance traveled by 60-80%.
  • Improved morale by a factor twice prior level.
  • Improved regulatory compliance by 98%.
  • Skills and training matrices set in place provide for cross-functional reams capable of handling volume surges.

Healthcare | Emergency Room 

Improvement Initiatives

Client Benefits Realized

The demand analysis allow the treatment centers to reset stocking levels of treatment carts in line with the demand. Local activities (skate boarding contests) accounted for the increase number of knee, elbow and head trauma treated. Doctors and nurses spent less time hunting for the right materials and implements. ​
  • Labor and Over-time reduced 5%
  • Maintained compliance and quality
  • $250k annual operating expense reduction

Lean Supply Chain

Improvement Initiatives

  • Operator Lead Times
  • Outside Services
  • Purchased Labor
  • Organization Alignment
  • Parts Spend
  • Repairs & Maintenance
  • Changeover Time

Client Benefits Realized

  • Lead time reduced from 49 days to 3 for sourcing
  • Labor and over-time reduced $6M
  • Maintained 98% on time delivery and 100% quality
  • $10.4M annual operating expense reduction
  • Saved $210k from 5S implementation
  • Integrated firm into $3B parent

Lean Procurement Utilizing Six Sigma

Improvement Initiatives

Defect: Process and tolerance variability.
DMAIC Project: Lean out the Supply Network, reduce
Supplier parts variability and install a pull replenishment model.

Client Benefits Realized

  • Supplier performance improved to better than 98% while reducing their inventory hold by 50%
  • Procurement lead-time was reduced from 4-5 weeks down to 1 day
  • Rework loops reduced from 10 to zero
  • Raw material inventory reduced by $3M
  • Complexity of procurement process vastly reduced
  • Non value adding steps eliminated