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It long has been recognized that the manufacturing sector is
the foundation for economic vitality in the United States.
Since 1995, The Corporation for Manufacturing Excellence (Manex) has provided a
broad array of proven solutions and resources exclusively to manufacturers, distributors
and their supply chains, enabling them to compete on a global scale. We use a
holistic and proven approach—from strategy through implementation— to impact all
facets of business performance. The results: growth, profitability, and competitive
advantage.
Contents
• About Us
• Philosophy
• Approach
• Services and Solutions
• Team
• Case Studies
• Contact Us
This document and its contents in their entirety are Copyright ©Manex. All Rights Reserved.
“There has been an amazing transformation in the operations
workforce with regards to Lean implementation. A complete
paradigm shift has occurred enabling each employee to feel and
know they are empowered to use the Lean tools. The 5S
principles of Lean have been implemented by the employees at an
astonishing rate, showing how this concept is now a belief.”
- Jes Vargas, Director of Operations
Z-World
About Us
Boost Performance
In today’s extremely competitive global environment, manufacturers and distributors face significant
challenges to improve business performance. Now, more than ever, innovative business practices are
essential to create a vigorous and sustainable future in manufacturing.
“A lack of innovation is the most serious challenge facing the U.S. manufacturing base, because global
competition will continue to force increases in productivity, movement of commodity manufacturing
overseas, and displacement of American labor.”
— Thomas W. Eagar and Christopher Musso, Massachusetts Institute of Technology
Forward-thinking U.S. manufacturers are rising to the challenge and prospering with the support of dedicated
partners like Manex. Manex helps companies turn business challenges into business opportunities. We
provide high-value consulting and business advisory services that help manufacturers significantly increase
growth, productivity, quality, and profitability.
We work with you holistically, with a proven approach and unique skills that deliver immediate results and
position you for long-term success, while enabling you to serve your current customers effectively without
undue distraction.
Every day, we help manufacturing companies of all sizes use innovative practices to implement real business
change and achieve competitive results.
About Us
Knowledge and Expertise
Our manufacturing expertise covers the extended value chain — from supply chains through manufacturing
and distribution — for a broad range of industry sectors including aerospace, automotive, bio-tech,
communications, consumer packaged goods, food, heavy manufacturing, high-tech, medical devices,
pharmaceuticals, and precision manufacturing.
Our diverse team brings an average of 20 years experience to deliver a powerful depth and breadth of
industry and business know-how — from strategy through operations. We are nationally recognized for our
strategic, enterprise-level expertise and extensive front-line manufacturing experience.
As a member of the National Institute of Standards and Technology (NIST) Manufacturing Extension
Partnership (MEP) program, we draw upon a national network of resources covering broad expertise in
manufacturing best practices. We work in partnership with MEP to solve your challenges by advancing best
practices in manufacturing operations, methods, and processes.
With this unique blend of expertise, we help you become stronger and ultimately more profitable.
About Us
Analytical Approach > Dramatic Impact
Our team uses a fresh, analytical approach to help drive complexity out of your business and facilitate
your success.
We quickly examine your existing business and operations to identify potential problem areas and leverage
points to transform your business. Working collaboratively with you, we establish priorities and implement
solutions that deliver the optimum financial and operational impact.
These objectives become the scorecard for our team. We systematically remove bottlenecks and roadblocks—
while developing new ways to create value — by continuously working with you throughout the process to
deliver the greatest return on investment.
Manex prides itself on your long-term results and business success. The business value we
provide is measured by an independent third-party (NIST) to ensure we meet and exceed your
business objectives.
“What was accomplished here in one week, with support from
Manex was extremely valuable and worthwhile. In all my years of
manufacturing, I do not recall output as tangible as what we have
just experienced. We are seeing visible, very positive changes in our
staff and in the quality of our products.”
- Rick Brown, VP of Operations
Westcor
Philosophy
Manufacturing Vitality
Manex operates under the principle that manufacturing and distribution are the cornerstones of the U.S.
economy, playing a central role in American prosperity as one of the most vital sectors for economic growth.
Our sole purpose is to help manufacturers and distributors navigate successfully through volatile market
conditions to gain a competitive edge. We help you deploy world-class manufacturing techniques to improve
productivity levels, shorten supply chains, and deliver more customer value.
With our roots in manufacturing, our active participation in MEP, and a longstanding dedication to knowledge
transfer and implementation, we have a continued commitment to develop and deliver services that help you
thrive in a competitive environment.
Your success is our measure of success.
Philosophy
Change Innovation
The key to success in today’s rapidly evolving environment is to use change as a competitive edge. With an
eye on creating value, Manex helps you become more agile, harnessing change to transform your enterprise.
Our team works closely with you, as a business partner, identifying and implementing ways to enhance your
strengths and stay ahead of the competition. We help you build tomorrow’s enterprise today; beyond
adapting to change; creating it.
With clarity of vision and exceptional discipline, we help you create a sustainable competitive advantage.
“Company president, George Whitehill stated that this is the best
cash flow position that AMS has ever been in. Where we are right
now sets the stage for us to become the Silicon Valley solution for
new product introduction as the cornerstone for us to go through
dramatic growth in the next couple of years.”
- Ed Bless, VP of Business Excellence
AMS
Approach
Integrated Effectiveness
We work with our clients using a holistic approach looking at the business as an integrated, cohesive whole.
By engaging all levels of the organization – from senior management to line operators – we quickly achieve
dramatic results that are sustained for the long-term. Our disciplined approach supports the alignment of
strategy, process, people, and technology to help you effectively achieve your objectives and exceed your
performance goals.
Our full range of integrated services is tailored to your unique business needs. Using proven methodologies
and tools, in-depth expertise, and innovative solutions, we help you implement business improvements for a
flexible, highly responsive enterprise.
Together our holistic approach and differentiated services translate into increased business value for
our clients.
Approach
Rapid ROI > Sustained Results
Our focus is to enable fast returns on your investment and sustained results. With our holistic approach, we
pinpoint high-impact process improvements and identify critical ways to streamline operations to quickly
achieve cost efficiencies and increased profits. Coupled with long-term strategic vision, we facilitate ongoing
alignment of manufacturing operations with your overall business objectives. We deliver tangible results and
the agility to adapt to changing needs and market realities. Our projects average more than
600% annualized ROI - that's a $6 return for every dollar invested in these activities after just
12 months.
Throughout the process, we share information, insights, and best practices helping your existing workforce
adopt process improvements throughout your value chain. Knowledge transfer ensures new practices are
sustained for long-term, measurable results.
Our comprehensive services connect business objectives to operational execution. We arm you with the tools
and knowledge to respond to customer demands more quickly, improve profitability, and drive down costs
throughout your organization.
Through a collaborative, results-driven approach, we help you transform your business to maximize your
return on investment.
“Working with Manex made the process seem very easy in terms of
efficiency and smoothness. Many companies could learn valuable
lessons from Manex. We look forward to working with Manex in the
future when the need arises.”
- David Allen, VP Manufacturing and Operations
Marinco
Comprehensive Services
Tailored Manufacturing Solutions
Manex offers a full range of high-value consulting and business advisory services for the manufacturing sector
that spans the entire supply chain.
By offering integrated services, we provide solutions that enable you to:
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Create and maintain competitive advantage
Position for sustained growth and profitability
Increase revenue
Improve efficiencies and reduce costs
Reduce costs across the supply chain
Optimize processes
Reduce cycle time
Manage for continuous improvement
To help you achieve quantifiable results we offer an integrated portfolio of offerings in the
following areas:
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Strategy
People
Process
Performance
Strategy
As your strategic business advisor, Manex helps you identify and create new sources of value and growth in
your enterprise. With a fresh, analytical look at your market environment, required core competencies, and
current state of operation, we help you identify opportunities and develop viable strategies to realize them.
Our experienced team works with you to clarify business objectives, prioritize and execute upon
corporate initiatives, and define and implement performance measures and processes that help you gain
sustained results.
Our services and solutions include:
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Corporate Strategy & Business Planning
Market Strategy
M&A Advisory; Post-M&A Integration
Organizational & Operational Design
Product Line Extensions/Rationalization
Manufacturing, Distribution & Channel Strategy
In/Outsourcing (Make/Buy)
Customer Satisfaction, Loyalty & Retention
People
With relatively high labor costs, U.S. manufacturers and distributors must seek out ways to compete on
productivity, product superiority, quality, and responsiveness to customer needs. These competitive
pressures put a high premium on the skills, morale, and commitment of employees.
With people as one of your greatest assets, Manex helps you enhance the skills and knowledge of your
workforce with innovative training and development programs. We specialize in providing comprehensive
solutions to ensure your workforce is skilled in advanced manufacturing methods and technologies to enable
future innovation in your enterprise. Through collaboration with universities and NIST, we deliver the latest
knowledge and thought-leadership in innovative manufacturing techniques to keep employees’ knowledge
and skills at the leading edge.
We help your employees – at all levels – develop the advanced skills required to meet the demands of an
increasingly complex environment.
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Knowledge Management
Management Leadership Training
Lean Operations & Six Sigma Training
ISO 9001-2000 Implementation & Certification Assistance
California ETP Training Funds
Process
The road to maximizing business performance frequently demands improving your enterprise’s core
processes. Our process consulting services align strategies, people, and technology with best-practice
business processes to deliver considerable business improvements and measurable outcomes.
Our proven set of best practices, supported by experienced professionals within manufacturing and
distribution, allow us to deploy customized high-value solutions to eliminate business process roadblocks
and waste, while simultaneously enabling growth. We identify opportunities for improvement through a
diagnostic review of current business processes, systems, and internal controls and determine whether
they add value and contribute to profitability.
Manex enhances your business performance by making complex customer requirements more
manageable through optimized and streamlined business processes. We specialize in helping
manufacturers and distributors increase revenues and reduce costs by refining and eliminating inefficient processes and by introducing and implementing advanced processes.
Our process consulting approach couples quantifiable savings with significant business improvements. Beyond
the manufacturing floor and throughout the organization, our team can show you innovative ways to deliver
business optimization across the value chain.
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Lean Operations
Six Sigma Quality Management
Activity Based Management
Process Design
Supply Chain Management
Procurement
Quality Management Systems
RCA, TQM, HACCP and cGMP
Performance
Manufacturing performance management is increasingly important as pressures to innovate continue to rise.
To be on the manufacturing forefront, companies must raise the bar on performance, quality, and cost with
continuous improvement efforts.
Manex helps develop and implement the right performance metrics to measure organization effectiveness
and its impact on profitability and productivity. We work with you to improve management decision making
with timely, relevant information important to achieving your business objectives. We implement processes
that automatically and proactively alert management to potential impacts, allowing you to make timely
decisions to optimize operations rather than simply react to events. Our experts help you implement best
practices, tools, metrics, and scorecards for competitive performance (with supporting what-if analysis) to
model impacts and create a closed loop process for continuous improvement.
We infuse performance management techniques in all of our services, knowing it is critical to the success of
your strategy, process, and people development initiatives.
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Executive Decision Support Systems
Internal/External Benchmarking
Management Dashboards & Scorecards
Activity Based Cost/Profit Management
Key Performance Indicators (KPIs)
Profit Optimization
Event Management
“The Manex team was instrumental in assisting our team during our
Value Stream Mapping Roadmap development sessions.
As a result, we have been working diligently on the
implementation of our Roadmap which has had significant impact
on reducing our lead time, increasing our quality and increasing our
value added activity during our processes.”
- Mauro Folena, Director of Operations
Coherent, Inc.
Team
In-depth Knowledge > Hands-on Experience
Manex offers a proven and experienced management team with extensive industry expertise and a
consulting team with significant experience in business strategy and manufacturing operations. We bring
applied knowledge and practical solutions, assisting diverse organizations optimize processes to drive down
supply chain costs, maximize the value of existing assets, and convert intellectual capital into profit.
With an average of 20 years of business strategy expertise and manufacturing experience, each of our
consultants has the industry skills and tools to quickly understand your needs, tailor solutions to meet your
business challenges, and deliver solid results. Our management team engages directly with you, utilizing a
wealth of experience in strategy, planning, and operations, to develop innovative solutions that deliver
important business benefits.
From business strategy and processes to hands-on implementation, we share experience and best practices
to help transform your business.
Our professional team is committed to your success.
Team
Name
Title
Education
Years of Experience
Gene Russell
CEO/Executive
Director
• BA - Economics University of California,
Los Angeles
Over 30
Name
Title
Education
Years of Experience
Nana Cho
Director of Corporate
Development &
Executive Consultant
• MBA - Cornell University
• BA - University of Southern California, Annenberg School for Communication
Over 15
Name
Title
Education
Years of Experience
Bill Browne
Director of Client Services
• MBA - University of Detroit
• BS in Engineering Arts - Michigan State University
Over 34
Name
Title
Education
Years of Experience
Gary Waters
• BA - Western Michigan
• Materials Management (APICS) & Purchasing (NAPM) Certifications
Over 33
Name
Title
Education
Years of Experience
Michael Levin
• BA in Marketing - Over 30
California State University,
Chico
 S trategy
 People
 Process
 Performance
Area of Expertise
 S trategy
 People
 Process
 Performance
Area of Expertise
 S trategy
 People
 Process
 Performance
Area of Expertise
 S trategy
 People
 Process
 Performance
Area of Expertise
 S trategy
 People
 Process
 Performance
Area of Expertise
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Corporate Strategy
Business Development
Sales and Marketing Operations Management
Process Improvement
Product Line Development
Corporate Strategy
Competitive Analysis
Benchmarking
Complex Project Management
• Business Strategy
• Lean Manufacturing
• Certifiied Six Sigma Master Black Belt (CSSMBB)
• Quality Systems
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Lean Manufacturing
Purchasing
Materials Management
Just-in-Time (JIT) Environments
Sales Training
Strategic Planning
Marketing Plans
Leadership Training
Presentation Skills Training
Team
Name
Title
Education
Years of Experience
Eric W. Wiedenmann
• MBA - Kellogg School of Management, Over 23
Northwestern University,
• BS in Marketing- Ashland University
 S trategy
 People
 Process
 Performance
Area of Expertise
• Strategic Marketing Plans
• Business Development & Sales Processes
• Competitive Intelligence
• Benchmarking
Name
Title
Education
Years of Experience
 S trategy
Area of Expertise
Philip Cullen
Senior Consultant
• MBA in Finance & International Business Santa Clara University
• BA in Physics - Sonoma State University
Over 22
 People
 Process
 Performance
• Statistical Process Control
• Continuous Improvement
• Engineering Change Mgmt
• Process Qualification
Name
Title
Education
Years of Experience
 S trategy
Area of Expertise
Richard Jeffrey Lewis
Management Consultant
Over 31
 People
 Process
 Performance
• Quality Management
• Maintenance & Safety
• Plant Operations Mgmt
• ISO 9001:2000 & OSHAs
• Project Management
Name
Title
Education
Years of Experience
 S trategy
Area of Expertise
Greg Cho
Senior Consultant
• BS in Electrical Engineering - University
of California, Davis
Over 9
 People
 Process
 Performance
• Supply Chain Management
• Production Management
• Six Sigma
• ISO 9001 Certification
Bios
Gene Russell
CEO/Executive Director
strategy people process performance
Overview/Background
Gene Russell is CEO/Executive Director of Manex and has over 30 years of senior executive strategic planning, operational
management, and consulting experience in the manufacturing and technology sector. With his extensive knowledge of
manufacturing operations, he has developed and implemented key strategic initiatives for companies, allowing them to improve
performance and achieve profitable growth. He has a strong background in sales and business development and a keen
understanding of manufacturing strategies in the global environment.
Prior to joining Manex, Mr. Russell led companies within several rapidly changing industries including telecommunications, wireless
mobile, consumer electronics, major appliances and most recently the fireplace and home décor segments. As CEO of Pilgrim
Home and Hearth for the past six years, he restructured operations in the U.S. and China, diversified and revamped product lines,
expanded distribution channels domestically and internationally, and developed a management team to produce record results.
Mr. Russell's previous experience consists of key leadership roles with a variety of manufacturing and technology firms, including
Oregon Scientific, Haier America, SOS Wireless Communications, SDI Technologies and AT&T. In these executive positions, he was
instrumental in developing new business plans, core operational improvements and diversified product plans, as well as launching
significant business development and sales initiatives. In start-up firms, he led new ventures with conceptual ideas, and developed
them into successful operating entities with industry leadership positions. He has also served as a board advisor and distribution
consultant.
Mr. Russell holds a B.A. in Economics from the University of California, Los Angeles. Areas of Expertise
• Corporate Strategy
• Business Development
• Sales and Marketing
• Business Transformation & Globalization
• Early Stage Management
• Distribution Management
• Product Line Development
• Operations Management
• Process Improvement
Bios
Nana Cho
Director of Corporate Development & Executive Consultant
Overview/Background
Ms. Cho has over 15 years of extensive consulting and industry experience, spanning several industries, including consumer
products, high tech, financial services, entertainment, and telecommunications. She has in-depth expertise leading and implementing
initiatives in the areas of corporate strategy, new product development, strategic alliances, and market analysis to help companies
improve performance and achieve profitable growth.
Ms. Cho’s industry experience includes holding several senior roles with Citigroup in New York and London where she analyzed
multi-regional acquisition options in the financial services market and formulated growth strategies to improve market leadership
positions across multiple business lines. In addition, Ms. Cho was a consultant with Mercer in their Communication practice.
Ms. Cho holds an MBA from Cornell University’s Johnson Graduate School of Management and a BA with honors from the University
of Southern California’s Annenberg School for Communication.
Areas of Expertise
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Corporate Strategy and M&A
Competitive Analysis and Benchmarking
Market Research
Financial Analysis
New Product Development
Complex Project Management
Representative Clients
AT&T Wireless, American Express Company, The J. Paul Getty Trust, Avnet, Inc., WebEx, Avery Dennison Corporation, WellPoint Inc.,
Allstate Insurance Company, The Walt Disney Company, Nestle, Citigroup, Inc., and Aramark Corporation.
Bios
Bill Browne
Director of Client Services
Overview/Background
Mr. Browne has over 34 years of extensive manufacturing experience and expertise in general management, manufacturing operations,
quality systems, engineering, product development and continuous improvement initiatives, including Lean Manufacturing and Six
Sigma. As an experienced change agent, he has led numerous process improvement initiatives resulting in top-line and bottom-line
growth across a range of industry sectors and geographies, including China, Hong Kong and the UK.
Prior to joining Manex, Mr. Browne was General Manager at Triangle Coatings, Inc. where he was responsible for managing two
manufacturing operations. During his tenure, he led the organization to achieve a 20% improvement in productivity. Previously, Mr.
Browne held executive management positions with a number of organizations including Morgan Crucible, Consolidated Container
Company and Mattel, Inc., where he was instrumental in driving cultural transformations that enhanced profitability, productivity and
efficiency. Under his leadership at Mattel Toys Hong Kong, the operations doubled production without adding resources through the
implementation of Just-In-Time manufacturing techniques. During his work with General Motors, he developed the process for the
Vacuum Insertion of Engine Pistons, resulting in a pre-patent research disclosure.
Mr. Browne has led numerous Lean Manufacturing, quality (ISO 9001, 8D), product optimization, consumer pricing and workforce
development programs that achieved dramatic improvements in productivity and competitiveness. He has led implementations in the
areas of Product Design and Optimization using DFMEAs and PFMEAs and was part of the implementation team for a J.D. Edwards
ERP system into an $80MM company. Mr. Browne has also achieved the Six Sigma Master Black Belt (SSMBB) and Certified Design
for Six Sigma (CDFSS). Mr. Browne holds an MBA with high honors from the University of Detroit, and a BS in Engineering Arts (a
combination of Engineering and General Business) from Michigan State University.
Areas of Expertise
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Plant/Operations Management
Supply Chain Management & Logistics
Lean Manufacturing & Six Sigma
Quality Systems
Project Management
General Motors, Mattel Inc., TRW, Inc., Triangle Coatings, Morgan Crucible Company, LLC, Consolidated Container, Kelsey Hayes
Company, Bretford Manufacturing, Diagnostics for the Real World, Wilkinson Manufacturing, Cellotape, Cytosport, Northrop
Grumman and Crossfield Products
Bios
Gary Waters
Overview/Background
Mr. Waters is a top-performing, solutions-driven consultant with more than 33 years of experience directing manufacturing operations.
An effective communicator capable of building professional relationships based on trust and mutual benefit, Mr. Waters’ years in the
manufacturing arena include positions as Plant Manager, Materials Manager, Purchasing Manager, and Technical Support Manager.
While working for several tier-one suppliers to Toyota and NUMMI, the General Motors/Toyota joint venture), Mr. Waters developed
his expertise in lean manufacturing and continuous improvement utilizing the Toyota Production System.
Mr. Waters holds a Bachelor of Business Administration degree in Business Management from Western Michigan and has earned
certifications in both Materials Management (APICS) and Purchasing (NAPM). He has also been featured in articles in Purchasing
Magazine and Ryder Resource Magazine.
Areas of Expertise
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Lean Manufacturing
Purchasing
Materials Management
Just-in-time (JIT) Environments
Health, Safety, Sexual Harassment, & Workplace Violence Education
Stress Management
Firestone Tire & Rubber, Johnson Controls, Trim Masters, Toyota, General Motors, KS Automotive, Inc., Protective Treatments, Inc.,
and Masco Corporation.
Bios
Michael Levin
Overview/Background
With over 30 years as an Entrepreneur and Small Business Consultant, Mr. Levin and his company, Custom Solutions Inc., offer Sales,
Presentation Skills and Business Development Consulting. Mr. Levin's personally developed methods, through years of entrepreneurial and
corporate experience, have provided highly successful results for Fortune 50 companies through start up entrepreneurial ventures.
Mr. Levin has delivered his unique message on radio and television shows around the country. He is the author of "How to Make Your Business
More Successful" and "How to Take Your Product to Market". He has spoken before numerous groups and corporations and has been
published in business and trade journals. He has also been featured in Entrepreneur Magazine.
As a successful entrepreneur, Mr. Levin has personally launched both product and service businesses from scratch and developed them into
multi-million dollar ventures. His products, including those he has patented, have been sold worldwide in over 30,000 retail outlets. He recently
sold his automotive marketing business that serviced over 130 dealerships in Northern California.
Mr. Levin was an executive with Pepsi Cola, running very successful divisions in San Francisco, Oakland and Reno, Nevada. He also consulted
for Pepsi, developing and delivering sales management training programs.
Mr. Levin received a BA in Marketing from California State University, Chico.
Areas of Expertise
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Sales Training
Strategic Planning
Marketing Plans
Leadership Training
Presentation Skills Training
Communication Skills Development
Pepsi Cola, Clorox, Oracle, Pacific World Corporation, DreamTime Inc., The Full Plate, Clocks Etc., Communication Catalysts,
Golden By-Products, Goodwin-Cole, Let's Play Recreation, Modular Rubber Drains, Millennium Molding, MBTechnology and numerous
entrepreneurs with new product launches.
Bios
Eric W. Wiedenmann
Overview/Background
Mr. Wiedenmann has over 23 years of in-depth expertise in sales, marketing and business development, helping organizations
increase profitability and improve competitiveness. As a management consultant, interim executive, and sales executive, he has
advised over 100 clients, including Fortune 500 companies, mid-sized firms and startups, in creating new sources of revenue and
generating profitable growth. His industry experience includes executive marketing and business development positions at Masco,
Avery Dennison, BP and CBC Industries.
Mr. Wiedenmann received an MBA from Kellogg School of Management, Northwestern University and a BS in Economics and
Marketing from Ashland University. He is an executive lecturer at Ashland University and has given business development speeches to
numerous CEO and COO advisory groups. Mr. Wiedenmann is also the publisher of “The Revenue Accelerator” newsletter and author
of “How to increase Sales in a Down Market”.
Areas of Expertise
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Strategic Marketing Plans
Business Development and Sales
Competitive Intelligence
New Market Penetration
Customer Satisfaction Benchmarking
New Product Launches
IBM, Fujitsu, TRW Automotive, Tru-Si Technologies, Inc., Turbolinux, Bradley Corporation, Masco Corporation, Avery Dennison
Corporation, BP, CBC Industries, and SGI.
Bios
Philip Cullen
strategypeople process performance
Senior Consultant
Overview/Background
Mr. Cullen has over 22 years experience as a project engineer and operations analyst, contributing to the successful execution of
product development projects in high technology manufacturing environments and national laboratories. As an experienced operations
specialist, he has developed, documented and automated manufacturing and test processes to reduce waste, reclaim materials and
enhance profitability. He has resolved critical process and supply chain issues, saving money and time, and directly contributing to the
intellectual property assets of organizations. Mr. Cullen has extensive experience with Agile product life cycle management software
and is a skilled strategist, capable of resolving problems at the procedural level to enable progress.
Prior to joining Manex, Mr. Cullen served in a variety of senior engineering positions in high technology environments, including Photon
Dynamics, Inc, SOI Direct, Nutool, Inc., Accucorp Technical Services and Read-Rite Corporation. His previous experience also includes
management of a technical group in Advanced Manufacturing Engineering at Lam Research, as well as research positions with the
Lawrence Berkeley Laboratory and the UC Berkeley Space Sciences Laboratory.
Mr. Cullen received an MBA in Finance and International Business from Santa Clara University and a BA in Physics, with a
concentration in Chemistry from Sonoma State University.
Areas of Expertise
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Device Manufacturing
5-Phase Project Management
Statistical Process Control
Lean Manufacturing
Continuous Improvement
Process Optimization
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International Operations
Engineering Change Management
Process Qualification
Yield Improvement
Cost Reduction
Process Planning
Photon Dynamics, Inc., Salvador Imaging, Lam Research, AccuCorp Technical Services, Read-Rite Corporation, Lawrence Berkeley
Laboratory, UC Berkeley Space Sciences Laboratory, Los Alamos National Laboratory, NASA, European Space Agency, Brelje &
Race Laboratories, Heller, Ehrman, White & McAuliffe, Courson Investments, ACWIB, Cellotape and Northrop Grumman
Bios
Richard Jeffery Lewis
Management Consultant
Overview/Background
Mr. Lewis brings over 31 years of extensive manufacturing experience assisting organizations in improving productivity and
transforming their operations. As an award-winning professional in leading quality management practices, he has in-depth expertise in
total quality management, maintenance management, safety harmonization, and ISO compliance. Mr. Lewis has led strategic
manufacturing initiatives in organizations across North America, Europe, and the Caribbean. His experience spans a number of
sectors including the manufacturing, food, semi-conductor, and energy industries.
Mr. Lewis is the recipient of the distinguished Quality Assurance Institute “Best of the Best” award for the best quality process
software. In addition, he is a highly accredited expert, as a quality management facilitator, principal auditor, and accredited ISO 9000
consultant.
Mr. Lewis is a frequent speaker at industry-leading conferences and has authored a number of articles in various industry
publications, including Maintenance Technology and Food Quality. He also has a U.S. Patent for Technical Safety Confirmation which
includes techniques for safety lockouts using a mobile device.
Areas of Expertise
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Quality Management Systems
Maintenance & Safety Management
Plant/Operations Management
ISO 9001:2000, OSHAS 18000, ISO 22000 & ISO14000
Project Management, Training & Facilitation
LJ Engineering, Inc., STG Machine, Hayward Quartz Technology, Inc., West Coast Quartz, Sequoia Brass & Copper, APPRO
Systems, Inc., Screen-Tech, Inc., SAE, Inc., NASAM, Inc., Pacific Rubber, and Semitec.
Bios
Greg Cho
Senior Consultant
Overview/Background
Mr. Cho is a highly skilled Senior Consultant with over 9 years of experience in manufacturing, production and supply chain
management. Mr. Cho's expertise includes supply chain integration, statistical analysis, Lean Manufacturing, Six Sigma and Quality
Management Systems.
Prior to joining Manex, Mr. Cho was a Quality Engineer with Sanmina-SCI where he analyzed and improved Supply Chain Quality
issues and developed new supplier processes to meet customer requirements. While in Manufacturing Management with Keola
Precision Technology, Mr. Cho managed projects and production, implemented Lean Manufacturing methods and led projects through
production life cycles. Mr. Cho also has experience in the implementation of ERP systems, assisting in the deployment of Epicor Vista
8.0 and administering company-wide shop floor data collection training. He has actively used Oracle 11i and Agile for data entry, data
extraction and report generation.
Mr. Cho has a BS in Electrical Engineering from the University of California, Davis. He is a Certified Quality Engineer (CQE) and has
achieved the Six Sigma Green Belt designation.
Areas of Expertise
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Supply Chain Management
Lean Manufacturing
Production Management
Six Sigma
ISO 9001 Certification
Applied Materials, ASML, Brooks Automation, Inc., Cellotape Incorporated, Cisco Systems, Flextronics, Holz Rubber Company,
Kirkhill Rubber Co., LAM Research, Martin-Baker America, Military Aircraft Parts, Novellus Systems, Inc., Sanmina-SCI,
Super Trap Inc., Yaskawa Electric America and La Tortilla Factory
“Manex has been a tremendous partner helping us with our Lean
transformation. With their in-depth expertise, on-site support, and
commitment to results, they have been instrumental helping us not
only achieve significant results to date, but also ensuring that we
have the processes in place to sustain them in the future.”
- Tommy Dockery, Western Region Manager
Del Monte Foods
Client Summary
Client Name
Industry
 S trategy
Solutions
Del Monte Foods
Food Products
 People
 Process
 Performance
• Lean Transformation
Client Name
Industry
 S trategy
Solutions
United Services
Transportation Equipment
 People
 Process
 Performance
• Lean Certification
Client Name
Industry
 S trategy
Solutions
Coherent, Inc.
Electronics
 People
 Process
 Performance
Client Name
Industry
 S trategy
Solutions
PowerLight Corporation
Energy
 People
 Process
 Performance
Client Name
Industry
 S trategy
Solutions
Northrup Grumann
Electronic Systems
Electronics
 People
• Leadership & Management Training Program
 Process
 Performance
Client Summary
Client Name
Industry
 S trategy
Solutions
T.G.I.F. Body Shop
Automotive
 People
 Process
• Comprehensive Lean Training Program
 Performance
Client Name
Industry
 S trategy
Solutions
Wilkinson Manufacturing
Metals/Machines
 People
 Process
 Performance
• Optimized New Facility Flow & Work Cell Layout
 S trategy
 People
 Process
 Performance
Solutions
Client Name
Industry
Max Machinery, Inc.
Metals/Machines
• ISO 9001:2008 Certification quality manual
• 6-Sigma DMAIC process
• Practical problem solving & Root Cause Corrective Action (RCCA)
Client Name
Industry
Goodwin-Cole Co.
Textiles - Tents and Awnings
 S trategy
 People
 Process
 Performance
Solutions
• Hi-impact marketing collateral
• Sales process
• Lead and cycle times
Client Name
Industry
Cellotape, Inc.
Printing/Labels
 S trategy
 People
 Process
 Performance
Solutions
• 5-year sales growth plan
• Current state and future state maps and layouts
• 5S and Lean Manufacturing
Client Summary
Client Name
Industry
 S trategy
Solutions
Pacific Biosciences
Biotech
 People
 Process
 Performance
Client Name
Industry
 S trategy
Solutions
La Tortilla Factory
Food
 People
• Facilities Layout with improved set up/changeover process
 Process
 Performance
• Additional Capacity
 S trategy
 People
 Process
 Performance
Solutions
Client Name
Industry
Millennium Molding
Plastics/Rubber/Composites
• Overtime and labor savings
• Marketing Strategy
• High Performance Website (SEO)
• Rebranding
• Revamped marketing methods/materials
Client Name
Industry
 S trategy
Solutions
Biotech Firm
Biotech
 People
 Process
• Operational Assessment & 5S
• Automation
 Performance
Client Name
Industry
Large Rubber Recycler
Recycling
 S trategy
 People
 Process
 Performance
Solutions
• Facilities Layout & Flow Processes
• Strategic Visioning
• Business Case Template for Customer Ordering Process
Client Summary
Client Name
Industry
 S trategy
Solutions
Cultured Marble Products
Construction/Contractors/
 People
 Process
 Performance
• Layout and Flow Analysis
Remodeling
• Comprehensive 5S training
• Lean Manufacturing, KPIs and PPE
• Quality and Critical Control Points
• Energy Assessment
Client Name
Industry
 S trategy
Solutions
Galaxy Desserts
Food Products
 People
 Process
 Performance
• Value Stream Mapping
 S trategy
 People
 Process
 Performance
Solutions
 S trategy
 People
 Process
 Performance
Solutions
Client Name
Industry
Crossfield Products
Corporation
Remodeling
Client Name
Industry
Gayler Construction
Remodeling
• Initial Implementation and "Tuning"
• Workforce Development Support
• Comprehensive Training Program
• 5S
• Strategy
• Management Facilitation
• Marketing Analysis
Client Name
Industry
 S trategy
Solutions
InsulTech LLC
Insulating Compounds
 People
 Process
 Performance
• High-level PPS Programs
• Re-layout of Office and Floor
• Kanban Replenishment System
Client Summary
Client Name
Industry
 S trategy
Solutions
Z-World
Electronics
 People
 Process
 Performance
Client Name
Industry
 S trategy
Solutions
Vicor - Westcor Division
Electronics
 People
 Process
 Performance
Client Name
Industry
 S trategy
Solutions
C&H Specialists
Metals/Machines
 People
 Process
 Performance
Client Name
Industry
Electronics
 S trategy
 People
Solutions
Advanced Material
Solutions (AMS)
Client Name
Industry
 S trategy
Solutions
Sequoia Brass & Copper
Metals
 People
 Process
 Performance
• ISO 9001:2000 Certification
• Comprehensive Supply Chain Management Program
 Process
 Performance
• ISO 9001:2000 Quality Management System
Client Summary
Client Name
Industry
 S trategy
Solutions
Applied Thin Film (ATP)
Semiconductor
 People
 Process
 Performance
• ISO 9001:2000 Certification
• Workforce Development
Client Name
Industry
 S trategy
Solutions
Morgan Hill Precision, Inc.
Metals/Machines
 People
 Process
 Performance
Client Name
Industry
 S trategy
Solutions
Cholestech Corporation
Health Care
 People
• Comprehensive Training Program
 Process
 Performance
• Business Communication Skills
• Experiment Design
Client Name
Industry
 S trategy
Solutions
Laird Manufacturing
Food Products
 People
 Process
• Deep Dive Quality Assessment & Value Stream Map
 Performance
• Kaizen Events
Clients
client >
Del Monte Foods
company profile >
Produces, distributes, and markets
premium, quality branded and private
label food and pet products. Market
leading brands in fruit, vegetable and
tomato products
client business need >
approach >
results delivered >
To accelerate the adoption of Lean across
the company, the Modesto California
Continuous Line was selected as a model
to showcase the substantial benefits of
transforming the line with the
implementation of Lean practices. This line
was chosen for its complexity in
operations - high volume of fruit, 24x7
operations, and seasonality. Achieving
significant productivity improvements in
this intricate environment would further the
rapid adoption of Lean practices throughout the company.
In collaboration with management, Manex
developed a comprehensive Lean program. A complete life cycle approach
was used - awareness, immersion,
implementation, and sustainability. An
in-depth assessment was performed to
understand the environment and determine
the key areas of focus and supporting
metrics. The team was immersed into Lean
with comprehensive training, tools, and
processes - 5S Visual Factory, TPM, standardized work, practical problem
solving, and cultural change activities.
Increased efficiency of its entire
Continuous Line with sustainable,
enterprise-wide improvements supported
by employees who are empowered,
engaged, and energized by a culture of
Lean. Specific results include:
•Improved Overall Equipment Effectiveness (OEE) by 4.7%
•Reduced scrap by over 30%
•Lean culture of continuous improvement (plant-wide training of 233 employees, owners and champions established, Kaizen events, Lean Management Center)
A fruitful transformation improves OEE by 4.7% and reduces scrap
by more than 30%.
Clients
client >
United Services
company profile >
Leader in full-service commercial
aviation global Maintenance, Repair &
Overhall (MRO)
approach >
results delivered >
United Airlines has made Lean a corporate-wide priority with the objectives
of creating a Lean culture committed to
increasing quality and productivity
throughout the organization. Since
November 2005, a strategic team has
been leading the charge for continuous
improvement across United Services. As
part of this priority, United Services turned
to Manex to help ensure the consistent
implementation of Lean through the
development of a Lean certification
program.
Working with the United Services leadership
team, Manex developed a powerful,
customized certification program to help
participants learn Lean principles and tools
to achieve measurable improvements. This
program was based on a consistent
standard developed by the leaders in
manufacturing excellence –the Society of
Manufacturing Engineers (SME), the
Association for Manufacturing Excellence
(AME), the Shingo Prize for Excellence in
Manufacturing. The certification program
modeled MRO processes within the company to accelerate participant learning.
Significant results include:
•185 employees, representing all departments, have completed the
program
•8 sessions: each with 32 hours of Lean curriculum, customized simulations and Kaizen Events
•Bronze Level Lean Certification Knowledge Certificates
•Innovative Partnerships: Grants and university credits provided in partnership with San Mateo County Community College District
Powerful Lean Certification Program standardizes Lean practices and
strengthens the organization.
Clients
client >
Coherent, Inc.
company profile >
World’s leader in Photonics, supplying
laser systems, components, laser measurement, control products, and precision optics to over 80 countries
approach >
results delivered >
Coherent’s global operations leadership
team wants to continue to build a culture
that is based on execution and
commitment to results, fostering a team
dedicated to high standards of quality,
leading edge technology, and continuous
improvement.
Manex helped the global operations
leadership team in Santa Clara implement
operational process improvements using a
systematic, holistic Lean methodology.
The comprehensive Value Stream Mapping
and roadmap of the Santa Clara operation
have led to the following results:
The Coherent global leadership team
engaged Manex to help institute Lean as
part of the company’s best practices by
evaluating key opportunities of
improvement within the Santa Clara facility.
•Improved collaboration with Material A three-phased approach was used to
focus on rapid implementation based on
near-term opportunities.
•Phase I: Assess (Value Stream Map)
•Phase II: Design (Implementation Roadmap)
•Phase III: Implement (Kaizen Implementation)
Management, Planning, and Manufacturing
• Reduced lead time in the RLS value stream from 9 days to 7 days
(22% improvement)
• Established flow manufacturing through enhanced material planning, better supplier communication, and consolidation of work areas
Value Stream Mapping helps drive significant operational improvements.
Clients
client >
PowerLight Corporation
company profile >
Nation’s leading designer and installer
of grid-connected solar
electric systems and energy
efficiency services
approach >
results delivered >
With PowerLight’s rapid growth, management was looking for ways to
improve operational performance by
reducing operating costs and improving
overall productivity with the implementation
of Lean Principles.
Manex helped PowerLight implement
operational process improvements by
delivering a one-week Kaizen Blitz based
on 5S Principles and Visual Control.
Through in-depth simulations, the
PowerLight team learned 5S methods
instrumental in identifying wasteful activities
throughout the organization. With this new
knowledge, the company has organized
two additional Kaizen events and made a
considerable impact on productivity.
The broad adoption of these practices has
resulted in the following performance
improvements:
•Over 20% reduction in work-in-process inventory
•20% reduction in lead time
•20% immediate productivity improvements
•Improved employee empowerment
5S methods widely adopted for productivity gains.
Clients
client >
Northrop Grumman Electronic
Systems
company profile >
World leader in the design,
development, and manufacture of
advanced electronics for military,
civil, and commercial use
approach >
results delivered >
Northrop Grumman uses a thorough
Performance Appraisal System to ensure
their employees operate at the highest
levels in the industry. The management
team of the Electronic Systems facility
wanted to ensure that their employees
exceeded the performance factors laid
out in the appraisal system.
Manex partnered with the University of
Santa Cruz Extension in developing and
delivering a comprehensive leadership and
management training program that
addressed Northrop Grumman’s seven
leadership factors — use of judgment
and initiative, employee coaching and
development, teamwork and process
improvement, communication, personal
effectiveness, framing strategy, and
customer focus. 35 key employees and
managers were trained in these areas,
significantly improving their overall
performance and commitment to results.
With the use of this program, employee
turnover was significantly decreased with all
of the trained employees continuing their
careers as leaders in the organization
(0% turnover rate among trained
employees). Overall, employee relations,
communication, and teamwork improved
across the facility as the trained employees
used the tools and techniques learned in
the program which ultimately increased
productivity.
Management training helps new division develop and retain key employees.
Clients
client >
T.G.I.F. Body Shop
company profile >
Full service auto repair business that
provides timely collision repair
services using the latest technology
and continuing education delivering
the highest levels of customer
satisfaction and quality
approach >
results delivered >
One of the challenges that T.G.I.F. Body
Shop is faced with is to become more
efficient in an ever demanding industry
which is in a technician shortage crisis.
The continuing education of their
employees is part of their plan to ensure
high levels of customer satisfaction
through the consistent delivery of superior
quality services. The owners turned to
Manex to enhance their employee skills
and make the business more efficient by
implementing Lean principles including a
5S Workplace Organization system and
Visual Factory.
Manex developed a comprehensive Lean
training program that included:
Significant results include:
•Increased sales by $500,000
•Phase I - 7 types of waste, employee empowerment, standardized work
•Phase II - 5S, Visual Factory and Kaizen
• Phase III - Implementation of 5S and Visual Factory on the shop floor and in the office
• Phase IV - Current state process
mapping, brainstorming, and future state mapping
• Retained sales by $50,000
• Workforce development of $15,000
• Increased employee morale
The owners of T.G.I.F. Body Shop have
continued to engage Manex in the
development and implementation of their
continuing education program for their
employees. Manex is currently providing
training on a number of different projects.
In-depth workforce development program drives productivity and
enhances competitiveness.
Clients
client >
Wilkinson Manufacturing
company profile >
Precision machine shop (metals and
plastics) providing product
development, prototyping, short-run
production and full production
services to customers in the building
and semiconductor industries
approach >
results delivered >
Wilkinson Manufacturing is currently
located in a 5500 square foot rented
facility and is planning to move to a new
8500 square foot owned facility to provide
the opportunity for a more functional layout
and room for growth, along with projecting
a more professional image to current and
prospective customers. An inadequate
layout can be highly detrimental to
productivity and consequently profitability.
Manex worked with Wilkinson Manufacturing
using a holistic, systematic approach to
develop an efficient flow for the new facility.
Continuous, efficient flow patterns of
materials, personnel and information were
implemented using consistent and
repeatable processes. Significant results
include:
Wilkinson engaged Manex to assist in
reaching their objectives for this new
facility
Key elements included:
•Optimizing “flow” and work cell layout in
the new facility (receiving/shipping and
production areas)
•Improving and sustaining workplace organization at the new site
•Improving productivity and quality/yield
•Providing a foundational understanding and initial implementation of lean
manufacturing
•Improved collaboration across the
manufacturing team
•30% improvement in throughput
•20% reduction in labor costs
•Workforce development improvements of $44,000
Optimized facility layout improves throughput by 30%.
Clients
client >
Max Machinery, Inc.
company profile >
Leading manufacturer of precision
flow meters and components for the
aerospace, semiconductor and medical
device industries.
approach >
results delivered >
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.
Manex used a proven, tailored approach
consisting of a detailed process map of the
operations from order entry through
shipping with a roadmap for improvement.
Actual activities included:
MAX dramatically increased production
levels, reduced annual operating costs,
improved quality and improved time to
market. MAX is positioned to exceed its
operational requirements and achieve ISO
9001:2008 certification. Specific results
include:
• Creation of current state process maps
• Implementation of proven Lean Manufacturing principles
• Implementation of two Kaizen Events along with Practical Problem Solving & Root Cause Correction Action (RCCA)
• Application of 6-sigma DMAIC Process
• Creation of the ISO 9001:2008 quality manual and supporting documentation
• 50% improvement in cycle time with $20K/year in cost savings
• 30% improvement in on-time-delivery
• 22% improvement in first-pass-yield
• 30% reduction in rework
• 35% reduction in ‘over-processing’
• 40% reduction in front office cycle times
• Improved quality and scheduling
Operational efficiencies lead to 30% improvement in on-time-delivery.
Clients
client >
Goodwin-Cole Co.
company profile >
Manufacturer of products made from
natural or synthetic textile fabrics,
including awnings, canopies, tents,
flags and industrial textile products
approach >
results delivered>
The company was finding itself in a
commoditized space with declining sales.
They were experiencing a continual decline
in the number of opportunities in the
marketplace.
The project consisted of 3 parts which
included, Strategy Development, Sales
Force Effectiveness and Lean
Manufacturing. Specific steps included:
The broad adoption of these practices has
resulted in the following performance
improvements:
• Identifying the company’s ideal markets •
•
•
by developing hi-impact marketing messages and collateral
• Altering the sales process by adding hi-impact facts and figures, allowing buyers to realize true long-term benefits
• Implementing Lean Manufacturing to identify and resolve key differences in the manufacturing process
• Reduction in lead and cycle times
• Increased sales close rate
Developed more than 60 viable leads for the company to pursue
Reduction in lead times by 20%
Cycle time reduction of 40%
Implementation of Lean Manufacturing results in 20% reduction in
lead times.
Clients
Client >
Cellotape, Inc.
company profile >
Leading manufacturer of high quality
labels for the Consumer Packaged
Goods Industry
approach >
approach >
Cellotape’s strategic acquisition of a
competitor resulted in two divergent
operations with an overlap in administrative
functions. The company’s executive
management team wanted to evaluate the
consolidation of both locations into one
site and implement operational
improvement through the utilization of lean
manufacturing. In addition, Cellotape
wanted to improve its total operational
effectiveness, reduce costs and improve
the "time to market" for designing and
delivering their innovative labels.
Manex used a tailored approach designed
to maximize the available floor space,
improve time to market on all products and
ensure the company had sufficient capacity
to support the company’s 5-year growth
plan. Manex implemented the following:
Cellotape dramatically increased production
levels, reduced annual operating costs,
improved quality and time to market.
Specific results included:
• 5-year sales growth plan
• “Machine uptime” improvement plan to meet capacity needs
• Current state and future state maps and layouts to optimize shop floor operations
• 5S and Lean Manufacturing principles to reduce costs and defects, and improve profitability
Over $600k reduction in operating costs
• 35% improvement in machine uptime
• Consolidation of plant operations
resulting in over $1.2 million in savings
• 80% reduction in non value added walk time for inspectors
• Reduction in order entry process by 35%
• 34% reduction in lead times
• 45% reduction in cost of labels
• Reduction of total energy costs by 35%
Implements world-class Lean Manufacturing to gain 32% in additional
capacity.
Clients
client >
Pacific Biosciences, Inc.
company profile >
Genome sequencing company
developing a transformative
singe-molecule DNA sequencing
platform
approach >
results delivered >
As a high performance organization,
PacBio identified Lean Manufacturing as a
critical way to achieve their strategic
objectives of increasing price performance
and overall capabilities in real-time DNA
sequencing.
Manex developed this three-step process
designed to achieve PacBio’s aggressive
process optimization and operational
improvement targets:
The implementation of Lean has helped the
organization improve productivity and
increase the efficiency of its opertions.
Specific results include:
• Teach the Concept (TC) – PacBio’s employees were trained in the concepts of Lean Manufacturing
• Prove the Concept (PC) – Trainees participated in Lean simulation exercises
• Implement the Concept (IC) – PacBio’s team identified opportunities to improve production processes, including a current state map, a future state map and then the requisite steps to attain the future state
•40% increase in productivity
PacBio turned to Manex as a partner to
transform their organization using Lean
Manufacturing because of Manex’s
holistic, collaborative approach,
comprehensive Lean knowledge, and
in-depth manufacturing expertise.
• Reduced floor space requirements by >50%, eliminating need for new building
• Doubled throughput in Surface Production
• Reduced cycle time by 68%
• Consolidated two “manufacturing areas” into one area without any downtime
• Provided comprehensive Workforce development through Lean Manufacturing training
Lean transformation drives a 500% increase in throughput.
Clients
client >
La Tortilla Factory
company profile >
Leading, worldwide manufacturer of
high quality tortillas and wraps for
domestic and international customers
approach >
results delivered >
The management team at La Tortilla
Factory recognized that in order to remain
a leader in their industry, they needed to
continually improve operational and
financial performance. They were
specifically interested in improving their
operations by increasing throughput. The
company also had excessive waste as part
of their value stream, leading to high
inventory levels. This led management to
search for an additional warehouse
location to house finished goods.
Manex used a proven, approach designed
to increase throughput and increase
warehouse space availability. Just-In-Time
philosophy was implemented, and the facility
layout was optimized. Specific actions were:
• Identifying high impact opportunities • Improving the line setup/changeover process using a Kaizen event
• Eliminating the need for an additional warehouse location through the ‘Make to Order’ Kaizen event
• Developing KPIs to sustain and measure improvement
• Benchmarking report for assessment
Dramatically reduced setup/changeover
time, increased inventory turns,
implemented new scheduling system,
eliminated the need for an additional
warehouse, and increased throughput.
Specific results included:
• Reduction of changeover time by 91%
• 40% increase in total yearly capacity due to the new scheduling system
• Reduction in overtime of $450K/year
and labor savings of $350K/year
• Estimated savings of $1M annually by eliminating the need for an additional warehouse location
• Improved flow/inventory management
Reduction in changeover time by 91% with additional capacity of
$2.6 million per year
Clients
client >
Millennium Molding
company profile >
Contract manufacturer of plastic,
rubber and composite parts,
specializing in recycled materials
approach >
results delivered >
Millennium Molding was interested in
developing a prioritized strategic,
marketing plan to determine which
companies/segments to pursue, evaluate
the best way to engage prospective
buyers and take advantage of existing
market opportunities.
Manex helped Millennium Molding
differentiate itself in the marketplace, using
its unique “engineered solutions” capabilities
and business model. Specific steps were:
• Established marketing strategy
• Conducted market research and identified opportunities
• Developed database of target customers
• Revamped marketing methods/materials
• Developed sales capabilities • Produced actual sales opportunities
• Created high performance website (SEO)
• Provided Content Management System
• Rebranded with high-impact messaging
With a new marketing strategy in place,
Millennium Molding has the necessary
tools to increase their visibility in the
marketplace and increase sales and
revenue. Specific results include:
•New website with enhanced style and content and improved SEO
• Marketing materials for sales meetings
• Database list of more than 35,000 leads
• Improved closure rate of sales calls
• Anticipated sales to CalTrans, HOAs, nurseries, other privates companies, retail, etc.
• Anticipated $600k in sales, translating to 3.1 million pounds of recycled rubber
New website with enhanced style, content and Search Engine
Optimization (SEO)
Clients
client >
Biotech Firm
company profile >
Developing an inexpensive, fast test
for infectious diseases, targeted to
serve the needs of developing
countries in Africa and Asia
approach >
results delivered >
This biotech firm applied and received
approval for assistance through NIH’s
SBIR Manufacturing Assistance Program.
Manex used a comprehensive approach to
document the current manufacturing
process, analyze and synthesize
opportunities and identify critical control
points (CCPs),
•Review of Current Manufacturing Operations – the development of a current state process to identify manufacturing
bottlenecks, CCPs and areas for
improvement.
•Automation Recommendations – Key processes were evaluated providing
specific recommendations to ramp for high volume production.
Specific productivity improvements include:
• Reduced the amount of labor required in the test strip manufacturing process by 30%
• Improved throughput in the reagent
copper and the reagent filler by 40%
• Improved throughput by 40% of the conjugates into tubes with vision
verification of presence for correct color and number
• Workforce development improvements of $10,000
In anticipation of demand and production
requirements to meet 100,000 units of
production per month (from 10,000), the
company engaged Manex to review and
understand their current manufacturing
processes with the objectives of identifying
bottlenecks, opportunities for improvement
and/or automation, and critical Control
Points from a quality perspective.
Automation dramatically improves productivity to scale for high
volume production.
Clients
client >
Large Rubber Recycler
company profile >
Handles the scrap tire needs for
companies across Northern California
approach >
results delivered >
With the accelerating growth of the scrap
tire market, this large west coast recycler
was looking for ways to improve their
competitiveness using creative approaches
to make high quality renewable products.
As a recycler of scrap tires, the company
gained assistance to achieve these
objectives through the Tire-Derived
Product Business Assistance Program
(TBAP) offered by the California Integrated
Waste Management Board. TBAP
provides targeted assistance to scrap tire
processors and tire-derived product (TDP)
businesses tailored to their unique needs.
As part of the Business Assistance Program
(BAP), Manex assessed, analyzed and
developed recommendations on a 4
component Activity Plan for the company.
•Facilities Layout & Flow Processes
•Strategic Visioning: To help determine the organization’s vision and metrics.
•Business Case Template for Customer Order Process: Enabled the company to select the best order for production
•Lean Manufacturing: Comprehensive 5S training with supporting Kaizen events
The insight, analysis and recommendations
provided by Manex, led to significant gains
in the productivity, profitability and
consumption of recyclable rubber.
•Improved utilization rates to 80% or higher
•Improved equipment and labor
efficiency rates of 80% or higher
•Identified areas to increase market
penetration and revenue with specific
classification of potential clients
•Provided comprehensive workforce development through Lean Manufacturing
Significant gains in the productivity, profitability and consumption of
recyclable rubber.
Clients
client >
Cultured Marble Products
company profile >
SF Bay Area leader in the
manufacture of custom-made Cultured
Marble, Granite and Onyx fixtures
approach >
results delivered >
Cultured Marble Products (CMP) engaged
Manex to analyze ways to improve upon
its operations on the manufacturing floor
and in the back office, while
simultaneously providing training to its
employees. These activities will be
instrumental in enabling CMP to improve
upon its efficiencies, achieve higher levels
of profitability, and ultimately produce
better products for its customers.
To achieve these objectives, Manex tailored
a phased approach with the CMP
management team.
• Product Flow Observations & Recommendations
• Product Flow Improvement Implementation
• Back Office/Finance Function Observations & Recommendations
• Energy Audit and Recommendations
• Continuous Improvement Activities and ETP Grant Support
• Additional Consulting and Training
This systematic approach has led to the
identification and implementation of
process improvements and standard work
practices across the operation:
Productivity increases significantly by 78%.
• 134% improvement in 5S score from Jun 07 – Jun 08
• 78% improvement in productivity
• 20% reduction in scrap
• 51% reduction in remakes
• 76% reduction in rework
Clients
client >
Scheid Vineyards
company profile >
Winery in Monterey County with 13
distinct vineyards, supplying grapes
for wineries in California
approach >
results delivered >
During the 2011 harvest season, SVI
provided access to their facilities,
personnel, and operations in order for
Manex to understand the harvest aspect of
vineyard operations. In exchange, Manex
provided consulting services to SVI in
order to help them improve harvest
operations.
Manex assisted SVI with the following goals:
The streamlined process and new mobile
harvest inventory tracking system will allow
SVI to operate more efficiently which will
result in significant cost savings.
•Calculate efficiencies gained through the deployment of a new mobile harvest inventory tracking system
•Define further opportunities to increase efficiencies, enhance communication, and drive costs down throughout the harvest operation
Manex detailed the SVI Harvest Process
on a ‘Process Map’ and identified areas for
streamlining with specific, realistic
improvements. These were mapped and
compared to the current state to calculate
the relative cost savings.
• Approximately $30,000 of time saved per harvest season with implementation of new mobile harvest inventory tracking system
• Approximately $400,000 of time saved per harvest season with additional opportunities for improvement identified in the project
Approximately $30,000 of time saved per harvest.
Clients
client >
Galaxy Desserts
company profile >
Worldwide leader in individual
desserts; developing, manufacturing,
and distributing company-branded
and private-label high-end unique
dessert items
approach >
results delivered >
Galaxy’s rapid and continuing growth
resulted in a move to a new production
facility. The executive team was interested
in implementing continuous improvement
initiatives as a precursor to its anticipated
expansion, as well as a foundation for
employee knowledge and skills to drive its
continued growth and profitability. Galaxy
wanted to explore operational
improvement opportunities in its croissant
line and packaging areas. Manex was
asked to assist in identifying and
implementing those opportunities and
provide training of Galaxy employees.
Manex used a proven, tailored approach
designed to maximize production efficiency
and quality, and to involve production
personnel to the greatest extent possible.
The team focused specifically on the
existing croissant line and existing
packaging area/team to drive high-impact
results, within these two critically important
areas. The tailored approach included:
As a result of these continuous
improvement initiatives Galaxy Desserts
dramatically increased production levels
within the croissant line. With improved
operational flow and production personnel
fully trained, the Galaxy team can more
effectively meet their profitability and
growth objectives. Specific results include:
• Value Stream Mapping • Initial Implementation and “Tuning”
• Follow-up
• Workforce Development Support
• Improved flow with new layout
• Increased throughput by 100%
• Reduced per unit cost by 20%
Improved operational flow increases throughput by 100%.
Clients
client >
Crossfield Products
Corporation
company profile >
World-class manufacturer of quality,
fluid-applied industrial flooring,
waterproof decking, marine decking
and decorative concrete overlays
approach >
results delivered >
With a sharp increase in sales, Crossfield's
manufacturing capabilities were stretched
to meet this increasing demand. Crossfield
was now looking for a way to concentrate
on operational excellence to help grow the
business and increase revenue even more.
Using a holistic approach, which included a
detailed assessment consisting of 12 key
business metrics benchmarked against
leading companies in the coating industry,
Manex developed a roadmap to help
Crossfield prioritize activities to support and
achieve their short and long term business
objectives.
With the implementation of this
comprehensive roadmap, Crossfield is well
on its way to achieving operational
excellence with significant impact to the
company’s top and bottom line. Lean
Manufacturing lies at the heart of these
measurable improvements.
The management team turned to Manex to
assess the current manufacturing
operations and identify opportunities for
improvement from order entry through
shipping.
Lean was used as the foundation for
continuous improvement. Manex trained the
workforce in 5S and the team implemented
process improvements and eliminated
bottlenecks throughout their operations.
Holistic approach drives 24% growth in sales.
• 24% growth in sales (year over year)
• 45% reduction in core materials costs
• 11% improvement in on-time shipments
•2 day shorter lead times
Clients
client >
Gayler Construction, Inc.
company profile >
Premier Design/Build firm that
specializes in residential and
commercial remodeling and
construction projects
approach >
results delivered >
Since the real estate decline, construction
and remodeling projects have decreased
markedly, requiring construction firms to
increase their proactive outreach efforts.
Gayler identified the need to refine its
processes in acquiring new business
opportunities (leads) while increasing the
capture rate of those leads. The company
turned to Manex to facilitate strategic
management sessions to identify specific
activities to increase revenue.
Manex provided a series of facilitated
sessions to identify high-impact activities the
Gayler management team could implement
to increase revenue. These specific activities
were focused on lead generation and
improving the close ratio of these leads.
As a result of these facilitated sessions, the
Gayler management team identified critical
ways to weather the soft real estate
market by repositioning their value
proposition to the industry with a focus on
their key differentiators.
•Clarify targets (revenue, growth, number •Qualified leads have doubled
of accounts)
•Lead generation and methods to
capture all sales opportunities
•Methods to identify leads
•Metrics and measures
• Close rate has increased by more than 75% (from 28% to over 50%)
• Millions in new business within 60 days of the close of the project
Millions in new business within 60 days of the close of the project.
Clients
client >
InsulTech LLC
company profile >
Leading manufacturer of high quality
insulating products used in
automotive, industrial, and aerospace
products
approach >
results delivered >
The management team was proactively
pursuing the implementation of Lean
Manufacturing in their Santa Ana
operations. InsulTech asked Manex to
design and implement a mentoring
program for key operations employees,
with the objectives of increasing process
efficiencies, improving the flow of
materials, reducing rework, eliminating
errors and maximizing customer order
performance.
Manex assessed the production
environment to create a prioritized roadmap
for “quick kit” improvements, used Lean
Manufacturing processes to increase
efficiencies, improve the flow of materials,
improve quality and decrease lead times.
Specific Results included:
• Trained 7 team members in 5S, Practical Problem Solving and
• Implemented two high level PPSs programs to support the CAT SQEP
• Assisted in the re-layout of the office to facilitate an error-free order entry system
• Created a Kanban replenishment system in the finished goods area
• Approximately 15% to 20% reduction in costs for order entry processing through the implementation of the action plans
• Anticipating a 10% to 12% reduction in costs on the production floor by eliminating waste (over production)
• Approximately 30% reduction in total inventory by reducing the amount of work in process between areas
• Secured new contract worth up to 7 million dollars with Fortune 50 OEM
Increased throughput and efficiencies results in multi-million dollar
OEM contract.
Clients
client >
Z-World
company profile >
Pioneer in the embedded controls
industry, providing high-performance,
reliable, embedded control solutions
approach >
results delivered >
Z-World was experiencing phenomenal
growth (over 30% annually), placing
extreme pressure on the manufacturing
operations to meet these customer
demands effectively.
Manex assisted the management team in
re-engineering their manufacturing
processes with the comprehensive
implementation of Lean Principles. To
begin the transformation, a two-day Kaizen
Event was held with the Operations Group
Management team and staff. Lean
Principles, Value Stream Mapping, and 5S
methods were employed with the team to
identify areas of improvement. Once
identified, Manex then worked with the
manufacturing team to implement these
changes, streamlining processes and
improving productivity.
An environment of continuous
improvement was developed as the
manufacturing operation embraced the
strategies and tools shared by Manex.
•Receiving/Inspection — Improved
workflow by 30%
•Final Test — Obtained 80% improvement in locating testing units
•Wave Soldering — Achieved 50%
efficiency improvements
New Lean culture drives manufacturing productivity improvements.
Clients
client >
Vicor – Westcor Division
company profile >
Designs, manufactures and markets
modular power components and
complete power systems used in the
communications, data processing,
industrial controls, test equipment,
medical, and defense electronic
markets
approach >
results delivered >
With heightened demand and intensified
competition, Westcor, a division of Vicor,
was looking for ways to simplify and
streamline its manufacturing processes of
more than 800 models of configurable
power supplies.
To increase quality controls and simplify
assembly methods, Manex introduced
Lean Manufacturing concepts using a
five-day cellular/flow Kaizen Event that
included immediate hands-on participation
of the manufacturing line. Within the event,
the overall work area was re-engineered to
improve cycle time, work-in-process
inventory levels, workflow balance, and
access to parts. This resulted in the freeing
up of capital equipment in two lines and
the elimination of three workstations
(from eight to five).
Westcor improved operational
performance with significant results:
•80% improvement in cycle time
•71% reduction in work-in-process
inventory
•$80,000 - $120,000 in labor savings
•35% increase in available floor space
•$18,000 savings in capital equipment
•Established a new culture of employee motivation, involvement, and empowerment.
Streamlined manufacturing process leads to substantial
operational efficiencies.
Clients
client >
C&H Specialists
company profile >
Provides manufacturing support
in the fields of electromechanical
assembly, sheet metal fabrication,
and frame construction, serving
contract manufacturers globally
approach >
results delivered >
C&H Specialists was facing intense
pressure to boost productivity and improve
on-time delivery performance in order to
remain competitive.
Manex developed a flexible
program using Lean Principles and 5S
methods to deliver immediate and
measurable results to their bottom line.
All team members within the critical
manufacturing departments — Inspection,
Shipping, and Receiving — were trained in
5S methods and Lean Manufacturing to
identify areas affecting productivity and
implement new processes to improve
operations. Tools and metrics were
implemented across the departments.
On-time delivery performance improved
significantly with the use of these tools
and processes. In the first month alone,
on-time delivery was increased from 54%
to 78%, while company-wide productivity
increased by 30% within the first two
quarters. Intrinsic to these improvements
was a new sense of employee
empowerment and team effectiveness.
Empowered employees boost productivity.
Clients
client >
Advanced Material Solutions
(AMS)
company profile >
Leading provider of customized
turnkey electronic manufacturing
services
approach >
results delivered >
Advanced Material Solutions (AMS) was
struggling with material shortages and
excessive defects in supplier parts. As a
result, productivity was hampered causing
AMS to fall far short of their production
goals. To make matters worse, profitability
was also suffering from poor management
of Purchase Price Variance (PPV).
Teaming with AMS, Manex designed and
delivered a comprehensive supply chain
management program. Manex developed
and deployed a five-week program,
implementing re-engineered processes that
eliminated parts and assembly receiving
problems while improving the PPV process
flow with a systematic approach. With
better control of parts, the manufacturing
line consistently met deadlines.
With the implementation of the improved
supply chain processes, AMS was able
to dramatically increase profitability and
improve productivity. Specific results
include:
•90% on-time delivery improvement
•66% PPV Flow improvement
•20% sales increase
•$500,000 inventory reduction
•$150,000 labor cost savings
Reengineered supply chain increases productivity and profitability.
Clients
client >
Sequoia Brass & Copper
company profile >
Supplier of nonferrous metals in plate,
bar and sheet form to the metal
fabrication industries in Northern
California
approach >
results delivered >
Faced with competitive pressures in the
marketplace and increasing customer
demands for more stringent quality
standards, the Sequoia Brass & Copper
management team determined the need to
implement a robust Quality Management
System using ISO 9001:2000 as its
foundation.
Manex assisted in the development of a
quality management system using
ISO 9001:2000 as the underlying
framework.
Operational efficiencies were gained with
the development and implementation of a
robust Quality Management System based
on ISO 90001:2000. Specific results
include:
• Identified and mapped organizational processes
• Developed organization’s quality objectives, policy and system
• Trained employees on the quality system and procedures for future training
• Established, implemented and documented procedures and metrics for critical manufacturing processes
• Developed a Quality Improvement program for quality and reliability
• ISO 90001:2000 certification
• Quality Management System with documented procedures for all critical processes
• Comprehensive procedures to ensure corrective action is taken when defects occur
• Better process control and flow resulting in improved product reliability
• Greater employee quality awareness
With ISO certification, customers will be
reassured that the company continues to
deliver on its commitment to the highest
levels of quality for products and services.
ISO Certification leads to highest levels of quality for products
and services.
Clients
client >
Applied Thin Film Products
company profile >
Leading provider of microwave
components and thin-film printed
circuit boards to the semiconductor
industry
approach >
results delivered >
To deliver on the company’s high quality
standards and service promise, ATP
engaged Manex to assist in the
implementation of a robust Quality
Management System using ISO 9001:2000
as its foundation. ATP strived to better
manage its processes and foster
teamwork by clarifying roles and
responsibilities, ultimately driving
productivity through process optimization.
Development of a Quality Management
System based on ISO 90001:2000 as the
underlying framework.
Operational efficiencies were gained with
the development and implementation of a
robust Quality Management System based
on ISO 90001:2000. Specific results
include:
• Identified and mapped organizational processes
• Developed organization’s quality objectives, policy and system
• Trained employees on the quality system and procedures for future training
• Established, implemented and documented procedures and metrics for critical manufacturing processes
• Developed a Quality Improvement program for customer satisfaction, quality and reliability
• ISO 90001:2000 certification
• Quality Management System based on ISO 90001:2000
• Better process control and flow resulting in improved product reliability
• In-depth training and education of 26 key process owners
• System to consistently measure quality
• Workforce development improvements
Quality Management System leads to operational efficiencies.
Clients
client >
Morgan Hill Precision, Inc.
company profile >
Job/Machine Shop specializing in the
fabrication of components for a
variety of materials including
aluminum stainless steel, copper,
brass, and plastic
approach >
results delivered >
As Morgan Hill Precision, Inc. continues to
focus on providing high quality solutions to
its customers, the management team
wanted to proactively pursue ISO
Registration to address client demand and
competitive pressures in the marketplace.
The management team of Morgan Hill
Precision engaged Manex to help them
establish an effective quality management
system and pursue ISO 9001:2000
Certification.
Manex assisted Morgan Hill Precision in the
development of its quality management
system using ISO 9001:2000 as the
underlying framework. A flexible program
was designed to effectively train the staff
while minimizing disruptions to the business.
Using a balanced approach, Manex ensured
the organization had the skills necessary to
effectively maintain their Quality
Management System going forward.
• Through this rigorous approach, the Company gained ISO 9001: 2000
certification in May, 2008
• Effective equipment maintenance has eliminated downtime completely for the last two months
• Product complaints have been reduced significantly by 50%
• The company has met planned
objectives and metrics for First Pass Yield and Supply OTD consistently for four months since Certification
Robust Quality Management System significantly reduces customer
complaints by 50%.
Clients
client >
Cholestech Corporation
company profile >
Provides easy to use, accessible
diagnostic tools and information to
health care practitioners in over 35
countries around the world
approach >
results delivered >
Cholestech is a competitive organization
focused on helping people live longer,
healthier and more active lives, their
passion is people - the people who benefit
from their solutions and the people of
Cholestech who make it all happen.
Manex developed a customized training
program tailored to the needs of
Cholestech. The program consisted of two
courses focused on improving business
communications skills and a third course on
experiment design. Each of these courses
was delivered by professional trainers with
extensive experience in each respective
discipline.
Using a blend of classroom instruction,
practical exercises, and real-world
examples, employees improved their
business communication and experiment
design skills.
With this strong concentration on their
people, Cholestech recognizes the
importance of developing the skills of their
workforce. As part of this effort,
Cholestech engaged Manex to enhance
their team’s skills in business
communications and experiment design.
•24 employees trained
• Increased employee morale
• Improved employee performance
• Improved employee teamwork
Team enhances skills through customized workforce
development program.
Clients
client >
Laird Manufacturing
company profile >
Leader in the manufacture, sale and
distribution of equipment designed for
the cattle industry
approach >
results delivered >
Laird has grown dramatically over the past
several years, achieving a significant
average annual growth rate of twenty
percent. To support this phenomenal
growth, the company is committed to
shaping an organization with a shared
culture and streamlined, efficient
operations built on a foundation of quality,
leading-edge technology and continuous
improvement.
Manex assisted Laird in building a strong
foundation of Lean using a proven advisory
approach and employing a world-class Lean
Enterprise Transformation model. Manex
carefully assessed Laird’s business and
processes, identified opportunities for
improvement, and then facilitated the
implementation of those processes
throughout the organization.
Laird gained significant improvements in
one of their most critical manufacturing
processes, pre-fabrication.
•71% improvement in safety
•17% reduction in rework
•19% immediate productivity improvements
•29% improvement in 5S
•Workforce development improvements of $30,000
Increased productivity by 19% in one of the most critical
manufacturing processes, pre-fabrication.
Contact Us
To find out more about how Manex can help you assess your current situation
and develop a roadmap for the future, please contact us:
Manex
The Corporation for Manufacturing Excellence
2010 Crow Canyon Place, Suite 320
San Ramon, CA 94583
1.877.33.MANEX
www.manexconsulting.com

view our corporate brochure

Transcription

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