Process Improvement Solutions Guide

What We Do

  • Increase Productivity
  • Reduce Scrap
  • Shorten Cycle Time
  • Right First Time Quality
  • Enable Staff With Correct Methods & Tools
  • Change Management

Complimentary 2 hour “7 Deadly Wastes” Workshop at your site

Click Here to Contact Stephen Wilkinson

“Steve is recognized as a consistent, high quality contributor. He delivered results exceeding the goals and continues to demonstrate good values and leadership attributes.”

Your 7 Wastes

  1. MOTION: Excess walking or movement by people, extra trips, meetings, searching for tools or materials.
  2. TRANSPORTATION: Excess movement of tolls or materials. Moving things from place to place. Deliver only to point of use, not staging areas.
  3. DEFECTS: Any mistake or error. Scheduling error, wrong material delivery, out of spec product or information.
  4. EXCESS INVENTORY (WIP): More parts, materials, raw materials, and computer processing than will be used in a very short period of time. Producing ahead of the schedule or before the customer needs it.
  5. OVER PROCESSING: Doing more steps or work than is required to meet customer demand. Over batching, creating scrap, packaging materials that are trashed. Excessive testing.
  6. WAITING/IDLE TIME: Watching an automated process or waiting for it to finish, waiting for a part or raw material to be delivered, waiting for a downstream vessel to be emptied to proceed to the next step. Waiting for schedule information or test results.
  7. EXCESS FINISHED GOODS: More finished product than the customer is demanding right now.

Tools To Eliminate Waste

  • Value Stream Map
  • Process map with additions of cycle time, hand-offs, staff level, scrap, distance, etc.
  • Spaghetti Diagrams
  • Find motion waste such as searching for tools, parts, information.
  • Time Study
  • How long does it really take to do a task and how much of that is really adding value?
  • Standard Work
  • Find the best practice, improve it, document it, standardize the method across all performers. Improves method and reduces variation.

“Steve works closely with managers teaching them how to Observe, Analyze, & Improve their processes. This direct coaching led to improvign multiple issues on the floor.”