Electronics Manufacturer Transformation

At a global manufacturer of electronic switches, Aegae worked with client site teams to transform production lines from a long, immobile, expensive lines with excess staff (who often walked hundreds of feet between two stations) to a tightly spaced U-shaped flow cell.

This flexibility from the newly integrated flow cells aided in improving efficiency and lowering costs. End customers benefited from predictable and flexible cells that were low cost, while finances benefited from continuous flow and standard WIP (asset velocity), less manpower (productivity) and ease of reconfiguration (growth).

With Aegae’s facilitation client production lines went from inflexible linear lines with operators having little multi-functional capabilities to a flow cell based on single piece flow with more predictable production (flexibility), standard WIP and less non-value added activity contributing to higher productivity. Below are the cell manufacturing metrics and how they improved under lean implementation:

Construction Turnaround

A major construction company was losing margin on each of their operating sites due to high rework and idle labor costs. Focused cost reduction at the site failed to staunch losses –

Aegae Practice Leaders observed multiple operations at multiple sites. APL’s performed an in-depth Value Stream Analysis learning that the root cause of the site losses were occurring in upstream processes before site construction operations commenced 

Aegae worked with the a cross functional team from the client to design and implement a project jump off process to verify operational requirements aligned with contractual obligations to the end customer. In addition key metrics were improved as well as shown below: