RESULTS

Wayne Russell & Associates - Manufacturing Consultants, Cost Reduction, Waste Elimination Industrial Engineer Consulting Consultant IE Lean Six Sigma Black Belt Cost Reduction Cost Savings Plant Layout Plant layout design AutoCAD Time Study Work Measurement Work Instructions Time and Motion Studies Line Balancing Cell Design Productivity Improvements Methods Analysis Value Stream Mapping Waste Elimination Muda Labor Standards Setting Time Study Training Green Belt Training Black Belt Training Lean 2 Green Training TIMWOOD Training Profitability Improvement Operations Assessment and Evaluation Services Metrics Development Interim Temp Contracting of Professional Services Lean to Green Lean2Green Lean and Green Lean2Green Manpower Utilization Optimization 8 forms of waste Lean Six Sigma Capacity Planning Toyota Production System Thru put and Flow Improvements Inventory Reduction Supply Chain Management Interim Engineers Interim Professionals Contract Work Coaching and Mentoring Standardized Work Facility Consolidations Facility Planning Project ManagementWayne Russell & Associates - Manufacturing Consultants, Cost Reduction, Waste Elimination Industrial Engineer Consulting Consultant IE Lean Six Sigma Black Belt Cost Reduction Cost Savings Plant Layout Plant layout design AutoCAD Time Study Work Measurement Work Instructions Time and Motion Studies Line Balancing Cell Design Productivity Improvements Methods Analysis Value Stream Mapping Waste Elimination Muda Labor Standards Setting Time Study Training Green Belt Training Black Belt Training Lean 2 Green Training TIMWOOD Training Profitability Improvement Operations Assessment and Evaluation Services Metrics Development Interim Temp Contracting of Professional Services Lean to Green Lean2Green Lean and Green Lean2Green Manpower Utilization Optimization 8 forms of waste Lean Six Sigma Capacity Planning Toyota Production System Thru put and Flow Improvements Inventory Reduction Supply Chain Management Interim Engineers Interim Professionals Contract Work Coaching and Mentoring Standardized Work Facility Consolidations Facility Planning Project ManagementWayne Russell & Associates - Manufacturing Consultants, Cost Reduction, Waste Elimination Industrial Engineer Consulting Consultant IE Lean Six Sigma Black Belt Cost Reduction Cost Savings Plant Layout Plant layout design AutoCAD Time Study Work Measurement Work Instructions Time and Motion Studies Line Balancing Cell Design Productivity Improvements Methods Analysis Value Stream Mapping Waste Elimination Muda Labor Standards Setting Time Study Training Green Belt Training Black Belt Training Lean 2 Green Training TIMWOOD Training Profitability Improvement Operations Assessment and Evaluation Services Metrics Development Interim Temp Contracting of Professional Services Lean to Green Lean2Green Lean and Green Lean2Green Manpower Utilization Optimization 8 forms of waste Lean Six Sigma Capacity Planning Toyota Production System Thru put and Flow Improvements Inventory Reduction Supply Chain Management Interim Engineers Interim Professionals Contract Work Coaching and Mentoring Standardized Work Facility Consolidations Facility Planning Project ManagementWayne Russell & Associates - Manufacturing Consultants, Cost Reduction, Waste Elimination Industrial Engineer Consulting Consultant IE Lean Six Sigma Black Belt Cost Reduction Cost Savings Plant Layout Plant layout design AutoCAD Time Study Work Measurement Work Instructions Time and Motion Studies Line Balancing Cell Design Productivity Improvements Methods Analysis Value Stream Mapping Waste Elimination Muda Labor Standards Setting Time Study Training Green Belt Training Black Belt Training Lean 2 Green Training TIMWOOD Training Profitability Improvement Operations Assessment and Evaluation Services Metrics Development Interim Temp Contracting of Professional Services Lean to Green Lean2Green Lean and Green Lean2Green Manpower Utilization Optimization 8 forms of waste Lean Six Sigma Capacity Planning Toyota Production System Thru put and Flow Improvements Inventory Reduction Supply Chain Management Interim Engineers Interim Professionals Contract Work Coaching and Mentoring Standardized Work Facility Consolidations Facility Planning Project ManagementWayne Russell & Associates - Manufacturing Consultants, Cost Reduction, Waste Elimination Industrial Engineer Consulting Consultant IE Lean Six Sigma Black Belt Cost Reduction Cost Savings Plant Layout Plant layout design AutoCAD Time Study Work Measurement Work Instructions Time and Motion Studies Line Balancing Cell Design Productivity Improvements Methods Analysis Value Stream Mapping Waste Elimination Muda Labor Standards Setting Time Study Training Green Belt Training Black Belt Training Lean 2 Green Training TIMWOOD Training Profitability Improvement Operations Assessment and Evaluation Services Metrics Development Interim Temp Contracting of Professional Services Lean to Green Lean2Green Lean and Green Lean2Green Manpower Utilization Optimization 8 forms of waste Lean Six Sigma Capacity Planning Toyota Production System Thru put and Flow Improvements Inventory Reduction Supply Chain Management Interim Engineers Interim Professionals Contract Work Coaching and Mentoring Standardized Work Facility Consolidations Facility Planning Project ManagementWayne Russell & Associates - Manufacturing Consultants, Cost Reduction, Waste Elimination Industrial Engineer Consulting Consultant IE Lean Six Sigma Black Belt Cost Reduction Cost Savings Plant Layout Plant layout design AutoCAD Time Study Work Measurement Work Instructions Time and Motion Studies Line Balancing Cell Design Productivity Improvements Methods Analysis Value Stream Mapping Waste Elimination Muda Labor Standards Setting Time Study Training Green Belt Training Black Belt Training Lean 2 Green Training TIMWOOD Training Profitability Improvement Operations Assessment and Evaluation Services Metrics Development Interim Temp Contracting of Professional Services Lean to Green Lean2Green Lean and Green Lean2Green Manpower Utilization Optimization 8 forms of waste Lean Six Sigma Capacity Planning Toyota Production System Thru put and Flow Improvements Inventory Reduction Supply Chain Management Interim Engineers Interim Professionals Contract Work Coaching and Mentoring Standardized Work Facility Consolidations Facility Planning Project ManagementWayne Russell & Associates - Manufacturing Consultants, Cost Reduction, Waste Elimination Industrial Engineer Consulting Consultant IE Lean Six Sigma Black Belt Cost Reduction Cost Savings Plant Layout Plant layout design AutoCAD Time Study Work Measurement Work Instructions Time and Motion Studies Line Balancing Cell Design Productivity Improvements Methods Analysis Value Stream Mapping Waste Elimination Muda Labor Standards Setting Time Study Training Green Belt Training Black Belt Training Lean 2 Green Training TIMWOOD Training Profitability Improvement Operations Assessment and Evaluation Services Metrics Development Interim Temp Contracting of Professional Services Lean to Green Lean2Green Lean and Green Lean2Green Manpower Utilization Optimization 8 forms of waste Lean Six Sigma Capacity Planning Toyota Production System Thru put and Flow Improvements Inventory Reduction Supply Chain Management Interim Engineers Interim Professionals Contract Work Coaching and Mentoring Standardized Work Facility Consolidations Facility Planning Project ManagementWayne Russell & Associates - Manufacturing Consultants, Cost Reduction, Waste Elimination Industrial Engineer Consulting Consultant IE Lean Six Sigma Black Belt Cost Reduction Cost Savings Plant Layout Plant layout design AutoCAD Time Study Work Measurement Work Instructions Time and Motion Studies Line Balancing Cell Design Productivity Improvements Methods Analysis Value Stream Mapping Waste Elimination Muda Labor Standards Setting Time Study Training Green Belt Training Black Belt Training Lean 2 Green Training TIMWOOD Training Profitability Improvement Operations Assessment and Evaluation Services Metrics Development Interim Temp Contracting of Professional Services Lean to Green Lean2Green Lean and Green Lean2Green Manpower Utilization Optimization 8 forms of waste Lean Six Sigma Capacity Planning Toyota Production System Thru put and Flow Improvements Inventory Reduction Supply Chain Management Interim Engineers Interim Professionals Contract Work Coaching and Mentoring Standardized Work Facility Consolidations Facility Planning Project ManagementWayne Russell & Associates - Manufacturing Consultants, Cost Reduction, Waste Elimination Industrial Engineer Consulting Consultant IE Lean Six Sigma Black Belt Cost Reduction Cost Savings Plant Layout Plant layout design AutoCAD Time Study Work Measurement Work Instructions Time and Motion Studies Line Balancing Cell Design Productivity Improvements Methods Analysis Value Stream Mapping Waste Elimination Muda Labor Standards Setting Time Study Training Green Belt Training Black Belt Training Lean 2 Green Training TIMWOOD Training Profitability Improvement Operations Assessment and Evaluation Services Metrics Development Interim Temp Contracting of Professional Services Lean to Green Lean2Green Lean and Green Lean2Green Manpower Utilization Optimization 8 forms of waste Lean Six Sigma Capacity Planning Toyota Production System Thru put and Flow Improvements Inventory Reduction Supply Chain Management Interim Engineers Interim Professionals Contract Work Coaching and Mentoring Standardized Work Facility Consolidations Facility Planning Project ManagementWayne Russell & Associates - Manufacturing Consultants, Cost Reduction, Waste Elimination Industrial Engineer Consulting Consultant IE Lean Six Sigma Black Belt Cost Reduction Cost Savings Plant Layout Plant layout design AutoCAD Time Study Work Measurement Work Instructions Time and Motion Studies Line Balancing Cell Design Productivity Improvements Methods Analysis Value Stream Mapping Waste Elimination Muda Labor Standards Setting Time Study Training Green Belt Training Black Belt Training Lean 2 Green Training TIMWOOD Training Profitability Improvement Operations Assessment and Evaluation Services Metrics Development Interim Temp Contracting of Professional Services Lean to Green Lean2Green Lean and Green Lean2Green Manpower Utilization Optimization 8 forms of waste Lean Six Sigma Capacity Planning Toyota Production System Thru put and Flow Improvements Inventory Reduction Supply Chain Management Interim Engineers Interim Professionals Contract Work Coaching and Mentoring Standardized Work Facility Consolidations Facility Planning Project ManagementWayne Russell & Associates - Manufacturing Consultants, Cost Reduction, Waste Elimination Industrial Engineer Consulting Consultant IE Lean Six Sigma Black Belt Cost Reduction Cost Savings Plant Layout Plant layout design AutoCAD Time Study Work Measurement Work Instructions Time and Motion Studies Line Balancing Cell Design Productivity Improvements Methods Analysis Value Stream Mapping Waste Elimination Muda Labor Standards Setting Time Study Training Green Belt Training Black Belt Training Lean 2 Green Training TIMWOOD Training Profitability Improvement Operations Assessment and Evaluation Services Metrics Development Interim Temp Contracting of Professional Services Lean to Green Lean2Green Lean and Green Lean2Green Manpower Utilization Optimization 8 forms of waste Lean Six Sigma Capacity Planning Toyota Production System Thru put and Flow Improvements Inventory Reduction Supply Chain Management Interim Engineers Interim Professionals Contract Work Coaching and Mentoring Standardized Work Facility Consolidations Facility Planning Project Management

 

The following are a few examples of actual client results provide during an engagement.
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CASE ONE:
RV Manufacturer

532% ROI
•
532% First Years Return on Investment.

•

Designed and implemented the progressive Line-Flow method of sanding, prepping and painting motorhomes.

•

 Identified and solved major bottleneck in the coach painting process thereby increasing quality and thru-put, decreasing WIP and overtime
•
 Identified and eliminated the over-use and wasting of expensive clearcoat, sealer and vinyl wash.

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CASE TWO:
Automotive Supplier

277% ROI
•
 277% First Years Return on Investment.

•

 Time studied and optimized manufacturing cells by balancing the work between operators, increased the machine speeds and increased cell output.

•

 Identified and eliminated wasteful/unnecessary work and improved the workplace methods.
•
 Trained all supervisors in Time Study which included classroom and shop floor proof of proficiency in doing a time study, checking and verifying machine cycle times and standard methods

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CASE THREE:

RV Manufacturer

 

261% ROI

•

261% First Years Return on Investment.

•

 Eliminated unnecessary Overtime.

•

 Implemented techniques to reuse and to reduce the wasting of very expensive raw materials.
•

Designed and implemented the first Lean manufacturing cells in the Cabinet Shop.

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During virtually every engagement there are associated tasks that are performed as a service by us that may not directly result in bottom line savings but are a necessary or a convenient relief to further help the client progress.

Some examples would be:

 •

Review resumes and assist in the interview and selection process when hiring Industrial Engineers or other technical employees.

•

 Working with vendors to negotiate lower prices on essential and usually expensive raw materials.
•
 Special project management, planning and cost tracking.
•
 Identifying problem employees or managers who are found to be serious hindrances or roadblocks to progress or change or in some cases unscrupulous activities or practices.
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In addition, the following are the highly publicized “TYPICAL RESULTS” of implementing Lean in virtually any environment:
•
Reduction in floor space requirements
•
 Reduction of lead time
•
 Reduction of inventory
•
 Reduction of scrap/defects/waste/errors
•
Reduction of labor costs
•
 Reduction of operating costs
•
 Increase in capacity
•
 Increase in productivity
•
 Increase in quality
•
 And much more

 

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