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.
Project Summary
Anderson Windows wanted to reduce its cycle time and manufacturing costs 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. The following are representative results:
| Metric | Improvement |
|---|---|
| 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 |