Conducting Lean Operations Programs:
Transforming assembly, machining plants, and warehouses into a world-class operative system, reducing manpower (by 25 to 30%), inventory (by 40 to 70%), and increasing capacity (by 20 to 60%) – eight plants
Enabling manufacturing companies to shrink production overheads (by 20 to 40%), focus on line management, quality, logistics, engineering, and maintenance departments – four companies
Enhancing Lean Culture elements such as Management on the shop-floor, collectiveness and communication programs which enable a continuous improvement rate of 10% to 20% per year – four studies
Automotive: Stepping up to The World Cup
Hungary has experienced strong growth in the automotive sector, but several trends, including investment shifts to low-cost countries, could threaten its success. The country has a number of options that can ensure it maintains its strength, including positioning itself as a near-shore R&D hub.
Sensitivity Training: Sizing up Your Manufacturing Footprint
Today’s complicated global manufacturing environment can make it difficult for companies to understand the impact of factors such as currency fluctuations, demand shifts, and energy price volatility on their production performance. A new approach to sensitivity analysis can enable them to work through the implications of different changes quickly and accurately.
How “Footprint DNA” Optimizes Production Networks
The global expansion of production networks can make improvement efforts more challenging, especially when complex products are involved. A new approach enables manufacturers to assess their production networks quickly and in a fact-based and actionable way, potentially reducing costs by 15 to 25 percent.
Lean in 48 Hours: Supercharging Supplier Management
With competitive pressure on the rise, automotive OEMs and tier-1 suppliers need to squeeze all the wasted value possible out of their supply chains. The 48-hour lean approach can help them supercharge this process and capture the savings they need to stay in the game.
Rightsizing Automotive Production in Western Europe
In today's tough business environment, automotive suppliers and OEMs can no longer operate factories at loss-making capacities and thus, must adapt their previously ad hoc international production networks to the new, more austere realities that face the industry today. Learn how to rightsize a global production footprint.
Greenfield Redesign Opens Doors to Expanding Capacity
Can a greenfield plant sprout from inside a brownfield shell? Find out, as a leading furniture manufacturer facing significant capacity constraints attempts to implement a successful radical redesign within the walls of its existing plant.
Turning Around a Bottleneck Automotive Plant
Can old plants learn new tricks? Find out, as an automotive supplier attempts to transform an aging, capacity-constrained facility into a textbook lean production powerhouse.
Greening a Brownfield – Building a New Lean Factory Inside an Old Plant
Building a new greenfield production system inside the walls of an old factory is sometimes the best way to increase capacity and productivity, and to keep a production network competitive. Learn more about growing a greenfield plant within brownfield walls.
Traffic Jam: Detecting Factory Bottlenecks
Bottlenecks have baffled plant managers since the very beginning when the first factory mass produced "widgets" – and detecting them remains a significant challenge. The constant changes that take place in any complex network of machines can make both spotting and tracking bottlenecks a difficult and constant struggle. Read on for an evaluation of six production facility bottleneck-detection methods and learn which one has been identified as probably the most promising.