HomeLean Manufacturing Assessments
Burns Bridge can provide comprehensive operational assessments to improve your efficiency, productivity, cost performance, on time delivery and bottom line. Burns Bridge has accumulated over 25 years of lean experience spread across the following businesses:
- Jobbing aluminum foundry (five years): Implemented work cell manufacturing together with a host of process and quality improvements, cutting square footage in half, reducing manning by over two thirds, doubling throughput and cutting lead time from six months to one week.
- OEM automotive piston casting cell (two years): Within 18 months transformed a 25 year poorly performing piston casting cell into a department with no scrap and no productive or maintenance overtime resulting in massive large positive budget variances.
- OEM automotive engine component machining (one year): On cam and piston machining lines, addressed a number of long term transfer line, bottleneck issues, while also, solving a number of very long term quality problems in less than 12 months.
- Tier 1 transmission component machining (one and one half years): Increased blanking throughput by 60% by implementing a number of improvements to the setup process (setup a tool room) and reducing machine tool downtime by addressing key cutting insert failure modes.
- Tier 1 stamping and robotic weld assembly (one year): By addressing downtime special causes and common causes in both the press shop and the robotic weld assembly shop increased bottom line profit by almost 100% from 12 million to 23 million per year.
- Tier 1 fuel and brake line assembly fabrication and test plant (three years): Achieved a more than tripling of productivity through the leak testing bottleneck allowing the plant to maintain healthy profit through a challenging economic period. Achieved a 100% on time metric through three years for quotes, prototypes, production part approvals, run at rates and ramp parts. Achieved a zero parts per million quality metric.
- Engineered to order pump manufacturing plant (three years): Achieved a 90% reduction in cost of quality while increasing on time delivery of pumps from 35% to over 95%.
- Aerospace and Defense manufacturer (one third year): Improved on time delivery of Boeing Dreamliner engine nacelle latch beams from 0% to 100% in less than 3 months.
- Consumer plastics recycling (one and one half years): In four months roughly quadrupled high density grind throughput from 15000 kg/day to over 60000 kg/day. Managed the installation of a 7 million dollar automated optical consumer mixed rigid plastics recycling line. Relocated and transformed a decrepit maintenance shop.
- High energy pump and turbo equipment repair service centres (over two years): Reduced cost of quality from 25% of sales to less than 1% in 9 months. Increased on time delivery from 0% to over 75% in 7 months. Achieved a best in 35 year throughput and bottom line result.
- Third party pump and turbomachinery repair service centres management (two and one half years): Put in place systems and processes to position two rotating equipment repair centres, positioning them to grow at a steady pace. Installed a quality system from scratch and received a quality certification in 12 months. Acted as the project manager to relocate the Edmonton shop into new quarters. Over a two year period increased the bottom line by a factor of six.
Burns Bridge has an expert level of knowledge related in lean manufacturing and process and quality improvement which can be brought to bear to improve your organization's productivity and bottom line..
