MAX MACHINERY
Max Machinery Inc. is a leading manufacturer of precision flow meters and components for the aerospace, semiconductor and medical device industries. Located in Healdsburg, California, it is a full service company with in-house sales, engineering, manufacturing, quality assurance and customer service functions.
Operational efficiencies lead to
30% improvement in on-time delivery.
“Max Machinery’s management goal in engagaing with Manex was to change our company culture from casual and uncontrolled, to formalized and controlled. While many opportunities for improvement remain, the initial goal has been achieved. The efforts put forth to achieve ISO 9001:2008 compliance have resulted in numerous improvements. In addition, Manex’ training in Lean Production methods (including Kaizen events, 5Why’s, root cause analysis, etc.) have given us the tools to improve the efficiency and productivity of our organization.”
– Dan Turek, General Manager, Max Machinery
Business Client Need
As Max Machinery continues to focus on providing high-quality solutions to its customers’ needs, the management team is proactively pursuing ISO Certification to address client demand and competitive pressures in the marketplace. Manex was asked to develop a comprehensive review of the operations and develop and implement plans that would immediately improve the company’s operations and cost structure, and prepare the company for ISO 9001:2008 certification.
Approach
Manex used a proven, tailored approach designed to maximize the program impact to Max Machinery. The program consisted of a detailed process map of the operations from order entry through shipping with a roadmap for improvement. Actual Activities included:
- Creation of current state process maps to understand the flow of products from order entry through shipping
- Implementation of proven Lean Manufacturing principles to reduce costs, reduce defects and improve plant profitability
- Implementation of two Kaizen Events along with Practical Problem Solving & Root Cause Correction Action (RCCA) training
- Application of 6-sigma DMAIC Process during the shop floor kaizen events
- Implementation of “train the trainer” concept on Lean Manufacturing Principles and for internal ISO 9001:2008 requirements
- Creation of the ISO 9001:2008 quality manual and supporting documentation in conjunction with Max Machinery personnel
Results Delivered
As a result of these continuous improvement activities, Max Machinery has dramatically increased production levels, reduced annual operating costs, improved quality and time to market. With improved operations flow and trained production team members, the company is positioned to exceed its operational requirements and achieve ISO 9001:2008 certification. Specific results include:
- 50% improvement projected in cycle time in the testing labs. This approximately amounts to $20K/year in cost savings
- Approximately 30% improvement in
on-time-delivery - Approximately 22% improvement in
first-pass-yield - 30% reduction in rework
- 35% reduction in ‘over-processing’ activities
- 40% reduction in front office cycle times
- Streamlined scheduling, which resulted in improved quality, decrease in
rework, rejects and scrap and improved on-time delivery - Decreased cost of lost opportunity