Privately held world class wire manufacturer whose products go into medical devices needed to reduce long lead times for custom products.
Facilitated kaizen event with cross-functional team to review all steps and teams involved (over 130 steps and 35 teams) and provided high level process map for further streamlining.
Client used event output to develop detailed process map and procedures to streamline the product development process.
Mining Downtime Reduction
UK Mining company needed to reduce downtime associated with Pullback Process of Continuous Miner. Severe winter caused low inventories and political concerns.
Facilitated kaizen event analyzing all steps of pullback, identifying waste and resource conflicts via a process map. Built future state map and action plan to reach it. Executed on next pullback tracking KPI’s.
Reduced downtime associated with pullbacks from one-week to 27.5 hours average, resulting in an additional 10% annual capacity.
Mining Program Development
Multinational mining company with $1.4B in annual sales, 3,100 employees, and 14 sites operating under different subsidiaries needed to offset inflation by improved productivity and establishing a continuous improvement culture.
Established Operational Excellence Process based on Lean Six Sigma principles including team, common roadmap, training, execution approach, project and results tracking, and assessment process over 8 years.
Met the annual goal of 3 to 5% reduction from 2008 through 2018 for a total of $165M in savings. Trained over 50% of the company on CI process execution. Executed dozens of projects each year.
Privately held global manufacturer of highly engineered food processing equipment needed to consolidate manufacturing operations into flagship site after purchasing a competitor, with minimal interruption in meeting customer orders.
Developed project plan for equipment layout, move, installation, and start-up with teams at both sites. Executed that plan.
Six-month project met budget and timeline with successful start-up of industrial laser, press brakes, welding equipment, compressed air system, and pollution controls. Met state and local building code and permit requirements.
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Lakehurst Consulting, LLC is a business and operational process consulting firm focused on helping clients eliminate waste and maximize profits.