Case Study: Turning Metal into Gold
Challenge:
The client, a CNC machine shop, was under increasing pressure to improve delivery times and quality from their largest customer. The shop had grown from a single lathe operator to a 250-person organization. While the staff were skilled craftsmen, they lacked scalable processes, a system of work, and managerial training. Most managers and supervisors were expert craftsmen who commanded respect on the shop floor but lacked formal management training.
Approach:
A customized System of Work was implemented, and supervisors were trained on management practices. The System of Work included specific elements such as Gap Analysis Meetings, a Training Matrix, Planning Meetings, a 72-hour locked schedule, Kick-Off Meetings, Short Interval Control, Loss Accounting, Transition Meetings, Quality Meetings, Production Review Meetings, Weekly Plant Review Meetings, and an Escalation Process.
In addition, a total of 67 task forces, corrective teams, and quick fixes were assigned to address problems, which engaged 97% of the employee base. These included conducting 5S throughout the shop, reducing Q-Notes, reducing setup time on jobs by 30%, organizing the programming and filing system, improving the tool crib’s efficiency, optimizing the folder flow system in the front office, and implementing human proofing to reduce errors and defects.
Impact:
The strategy led to significant improvements:
A 33% improvement in productivity and quote accuracy
A 25% improvement in scrap and rework rates
A 75% improvement in On-Time Delivery
A reduction in turnover and a more engaged workforce through the corrective teams and task forces
“This was transformational! What they showed me I use at home with my wife to make sure we are on the same page. They engaged everyone to help us achieve the goal. When we decided to bring in consultants, I thought they were going to fix us, but they just showed us that deliberate way. We fixed ourselves! We are sorry to seen them go!”
