The promise of Lean Six Sigma is that the enterprise can deliver products, services, value, and so forth “on demand.” The vigor and competitive advantage of a “real-time” organization is relentless, but only achievable through the improvement of “end-to-end” processes.
Anderson Windows wanted to reduce its cycle time as well as manufacturing costs in order to preserve its reputation and competitive position as a premier manufacturer. Through a pilot program, Lean Horizons implemented a Lean Transformation of one complete product line, providing both a holistic solution and a vision of the vitality of a Lean Enterprise. By implementing a robust S&OP process and heijunka – level scheduling, the client was able to transform manufacturing and distribution operations. Following are representative results:
|Required Manufacturing Space||– 18,000 sq ft|
|Shop Floor Inventory||– $600,000|
|Operator Travel Distances||– 90%|
|Delivery Lead Time||– 43%|
|Additional Revenue from a Single Line||+ $1,200,000|