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view our corporate brochure
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: • • • • • • • • 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: • • • • Strategy People Process Performance Comprehensive Services 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: • • • • • • • • 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 Comprehensive Services 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. Our services and solutions include: • • • • • Knowledge Management Management Leadership Training Lean Operations & Six Sigma Training ISO 9001-2000 Implementation & Certification Assistance California ETP Training Funds Comprehensive Services 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. Our services and solutions include: • • • • • • • • Lean Operations Six Sigma Quality Management Activity Based Management Process Design Supply Chain Management Procurement Quality Management Systems RCA, TQM, HACCP and cGMP Comprehensive Services 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. Our services and solutions include: • • • • • • • 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 Executive Consultant • BA - Western Michigan • Materials Management (APICS) & Purchasing (NAPM) Certifications Over 33 Name Title Education Years of Experience Michael Levin Executive Consultant • 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 • • • • • • • • • • 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 • • • • • • • • • 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 Executive Consultant • 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 • Lean Manufacturing • 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 • Lean Manufacturing • 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 strategy people process performance 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 • • • • • • 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 strategy people process performance 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 • • • • • Plant/Operations Management Supply Chain Management & Logistics Lean Manufacturing & Six Sigma Quality Systems Project Management Representative Clients 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 Executive Consultant strategy people process performance 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 • • • • • • Lean Manufacturing Purchasing Materials Management Just-in-time (JIT) Environments Health, Safety, Sexual Harassment, & Workplace Violence Education Stress Management Representative Clients Firestone Tire & Rubber, Johnson Controls, Trim Masters, Toyota, General Motors, KS Automotive, Inc., Protective Treatments, Inc., and Masco Corporation. Bios Michael Levin Executive Consultant strategy people process performance 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 • • • • • • Sales Training Strategic Planning Marketing Plans Leadership Training Presentation Skills Training Communication Skills Development Representative Clients 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 Executive Consultant strategy people process performance 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 • • • • • • Strategic Marketing Plans Business Development and Sales Competitive Intelligence New Market Penetration Customer Satisfaction Benchmarking New Product Launches Representative Clients IBM, Fujitsu, TRW Automotive, Tru-Si Technologies, Inc., Turbolinux, Bradley Corporation, Masco Corporation, Avery Dennison Corporation, BP, CBC Industries, and SGI. Bios Philip Cullen strategypeople 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 • • • • • • Device Manufacturing 5-Phase Project Management Statistical Process Control Lean Manufacturing Continuous Improvement Process Optimization • • • • • • International Operations Engineering Change Management Process Qualification Yield Improvement Cost Reduction Process Planning Representative Clients 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 strategypeople process performance 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 • • • • • Quality Management Systems Maintenance & Safety Management Plant/Operations Management ISO 9001:2000, OSHAS 18000, ISO 22000 & ISO14000 Project Management, Training & Facilitation Representative Clients 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 strategypeople process performance 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 • • • • • Supply Chain Management Lean Manufacturing Production Management Six Sigma ISO 9001 Certification Representative Clients 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 • Lean Transformation Client Name Industry S trategy Solutions Coherent, Inc. Electronics People Process Performance • Lean Manufacturing Client Name Industry S trategy Solutions PowerLight Corporation Energy People Process Performance • Lean Manufacturing 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 • Lean Manufacturing • ISO 9001:2008 Certification quality manual • Lean Manufacturing • 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 • Lean Manufacturing • 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 • Lean Manufacturing 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 • Lean Manufacturing 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 Construction/Contractors/ Remodeling Client Name Industry Gayler Construction Construction/Contractors/ Remodeling • Initial Implementation and "Tuning" • Workforce Development Support • Lean Manufacturing • Comprehensive Training Program • 5S • Strategy • Management Facilitation • Marketing Analysis Client Name Industry S trategy Solutions InsulTech LLC Insulating Compounds People Process Performance • Lean Manufacturing • 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 • Lean Manufacturing Client Name Industry S trategy Solutions Vicor - Westcor Division Electronics People • Lean Manufacturing Process Performance Client Name Industry S trategy Solutions C&H Specialists Metals/Machines People Process Performance • Lean Manufacturing 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 • ISO 9001:2000 Quality Management System • Workforce Development Client Name Industry S trategy Solutions Morgan Hill Precision, Inc. Metals/Machines People • ISO 9001:2000 Quality Management System 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 • Lean Transformation 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) client business need > 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 client business need > 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 client business need > 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 client business need > 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 client business need > 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 client business need > 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. client business need > 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 client business need > 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 client business need > 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 client business need > 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 client business need > 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 client business need > 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 client business need > 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 client business need > 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. Specific results include: •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 client business need > 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 • Workforce development improvements of $290,000 Clients client > Scheid Vineyards company profile > Winery in Monterey County with 13 distinct vineyards, supplying grapes for wineries in California client business need > 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. Specific results include: • 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 client business need > 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 client business need > 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 client business need > 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 client business need > 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 client business need > 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. Specific results include: •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 client business need > 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 client business need > 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 client business need > 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 client business need > 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 client business need > 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 client business need > 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. Specific results include: • 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 client business need > 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. Specific results include: 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 • Workforce development improvements of $20,000 • 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 client business need > 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. Specific results include: •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
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