lean enterprise and continuous improvement engineering

Slide Design© Duarte, Inc. 2014

LEAN ENTERPRISE AND CONTINUOUS IMPROVEMENT

ENGINEERING

Thinking Lean

From Design To Production

MARK KREITINGER


Lean and Continuous Improvement Engineering

+Apply Six Sigma and Lean Tools from design to production

+Improve processes and product development

+Investigate and troubleshoot production difficulties

+Identify and reduce waste

Improve Think Lean Troubleshoot Eliminate

02 03 04 01


© Duarte, Inc. 2014

THINK LEAN

01


Think Lean

Throughout the product life cycle, from design to production

At Munro and Associates,

a study of a client’s

product showed that

complying with regulations

had caused ineffective

fixes

Developed a solution

for the client that

allowed to redesign

their product to meet

current and new

regulations and

reduce parts

The proposed

redesign represented

$8M in savings to the

client by using a new

design.

A study of the Cummins

generator, and the

competitor’s product

revealed significant

design differences

Demonstrated a way

to reduce cost per unit

by reducing number

of parts, using

analytics from Design

Profit Software

The information from

comparative analysis

positioned the

company’s product to

better compete in the

market.

Polaris acquired

Timbersled, a

snowmobile kit

manufacturer whose

product had high

production costs

Conducted a study of

one part of the

product and analyzed

for cost reduction and

part reduction

opportunities by using

Design Profit

The result of the

study demonstrated

savings of $140K.

With further analysis,

there is potential for

exponential savings.

Work area layout and

engine tear-down

procedures at Polaris,

offered opportunities for

improvement

Conducted Kaizen

events with team

members across

multiple functional

groups

As a result of the

events, we were able to

implement an

improved work area

layout and created

documentation for the

tear-down procedure



IMPROVE

02


Improve Seek opportunities to improve processes using changes to product specifications and test to verify results

Collection boxes at the

Post Office made

handling mail

cumbersome

Suggested an

improvement to mail

box design in order to

make the process of

handling mail more

efficient

Obtained a degree in

Mechanical

Engineering, since it

was the Post Office’s

requirement to

redesign mail collection

boxes

TMI, a casework and

countertop

manufacturing company

needed to improve their

assembly process

Gathered over 100

ideas by performing

tasks at all work and

assembly stations.

Project revealed

potential risks to

worker safety. To solve

it, designed an

automatic stop to

increase efficiency and

prevent injury

At the metal paint

department at Polaris,

their paint line was setup

in a limited space and had

to handle loading and

unloading of parts, which

caused significant

downtime

Designed a new

layout and moved

loading and unloading

offline and in a

different location

Material movement

was improved and

the need for

downtime was

eliminated

At Cirrus Design, their

aircraft build rate was

not meeting their goal of

two per day

Analyzed workflow

and identified the

need to add one more

ply cutter

The addition of

another ply cutter

allowed to reach the

goal of building two

aircraft per day



TROUBLESHOOT

03


Troubleshoot

Seek opportunities to identify, troubleshoot and correct production difficulties

The metal paint

department at Polaris had

an issue with an

inadequate oven stop on

the conveyor line in which

parts had to cure for a

certain amount of time

Redesigned the stop to work at a 45

degree angle, opposed to working

completely horizontally.

This resolved the issue that was

causing the stop to fail.

The solution was effective,

even though the supplier of

the conveyor line had

communicated to Polaris

that it could not be done



ELIMINATE

04


Eliminate

Use analysis to identify opportunities to eliminate waste throughout the organization

Eclipse Aviation, a startup

company, was trying to

obtain type certification for

their Eclipse 500 aircraft

Conducted a company-

wide process audit

After implementing the

process and training

the organization,

Eclipse Aviation

obtained type

certification for the

Eclipse 500 six months

ahead of schedule

Audit revealed substantial

gaps in communication

between functional

groups. There was a

breakdown in the hand-off

process from group to

group.

Discovered that most

employees were not

aware of how to establish

a relationship with the

FAA for aircraft type

certification

Wrote a procedure to eliminate

gaps, which caused waste of

time and resources

Documented the procedure

manually, before automating it

using SAP

Obtained buy-in from senior

leadership and trained 250+

employees in how to implement it


MARK KREITINGER

Over 20 years of

comprehensive

experience in multiple

industries such as

manufacturing, aviation,

automotive, emission

solutions, power

generation and sports

and utility vehicles.

Lean Engineering and Continuous Improvement Professional

Highly knowledgeable in

lean enterprise

processes, focused on

cost reduction and

weight reduction

practices applied in end-

to-end product design.

An innovative individual

with a proven 7-step

process to assist

organizations and

facilitate the intersection

between engineering

and manufacturing.

608.609.0032

[email protected]

Linkedin.com/in/markkreitinger

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