Lean & Quality Management System Implementation

Lean and System Success for Manufacturing

A small company in Gardner, MA requested us to apply for a grant to provide training for their organization. The organization provides assembly and packaging services to customers. At the time of the grant they were about at the breakeven point in sales and looking to double the business. However there were several issues holding them back from growing, lack of capacity, inefficient processes, and untrained people to help them grow.

We created a training program to implement Lean and Six Sigma, ISO 9001:2015 and train them on how to improve the business. During the Lean training we worked on several projects to enhance their capacity and address inventory issues.

The Lean teams:

• Implemented 5S to double manufacturing capability
• Increased capacity to take on six new clients
• Tripled profitability while reducing cost in manufacturing
• Enabled increase in manpower for meeting new client needs
• Created a more pleasant workplace toward higher employee satisfaction

Together during the ISO training, we:

• developed all the necessary documents for the quality management system.
• implemented controlled processes and trained appropriate personnel.
• completed pre-registration preparation, and have contracted registrar for audit.
• implemented work instructions on each product, reducing errors by over 20%, and increased overall customer satisfaction.