Manufacturing Optimization and Lean 6σ Continuous Process Improvement Consulting Services
839 Alleghenyville Road Mohnton, PA 19540-7708
Tel. 610-914-1356 email: lpeterson@aftan.com
& Continuous Process Improvement
Read this page to discover
- how Continuous Improvement can be used to re-instill the entrepreneurial, creative spirit in all employees to discover low-cost, low-risk opportunities that can have significant positive impacts on business;
- why Lean Six Sigma is the ideal approach to implement a Continuous Improvement program; and
- why using Aftan Engineering is the best way to quickly implement and enjoy the benefits from Continuous Improvement.
Core Principals of Continuous Improvement
- reduce resistance and red tape;
- can have significant effects on improving efficiency and reducing costs when applied across the entire organization; and
- produce faster results and encourage more participation in the Continuous Improvement Program.
- yield major improvements on a specific challenge; and
- produce excitement in an organization for the breakthrough improvements of one challenge to be achieved on the next challenge
No one knows more about a process, the associated problems, and how to improve it than the person actually using it every day. People are also more likely to implement changes without resistance if the improvement was a peer's idea. However, to be successful and encourage employees to participate in Continuous Improvement,
- the work environment must assure employees will not get into trouble for noting problems;
- immediate supervisors must understand that having subordinates identifying areas for improvement is not a negative reflection on their job performance but rather a positive reflection of their leadership; and
- lastly, employees must receive recognition for their suggestions and improvements.
How much time and/or dollars has the improvement saved?
What are the projected savings if the revised process is implemented across the entire organization?
Many Continuous Improvement Programs fail to measure results or control the solutions that have been implemented to ensure that they will be sustained. Failing to control or standardize the newly implemented solution can lead to a reversal back to the old way of doing things.
Lean Six Sigma Continuous Improvement Tool Combines Two Proven Methodologies
- Over Production - producing more product than is required to fill orders and maintain optimum inventory.
- Idle (Wait) Time - time waiting for product to arrive at the next step in production.
- Delivery (Transportation) - unnecessary movement of materials and products.
- Motion - unnecessary motion by workers when producing products.
- Inventory - having more raw materials necessary to fulfill production requirements or finished good inventory required to satisfy customers' needs.
- Extra Processing - adding more work or quality to the product than is required to satisfy customers' needs.
- Rejected Parts (Defects) - product that must be discarded or reworked because it is not within specifications.
- Non-utilized Talent Waste - not fully utilizing workers experience, skills and knowledge.
Some Lean methodology tools include:
- Kaizen;
- Kanban;
- Visual Management;
- Line Balancing;
- Schedule Leveling;
- Value Stream Mapping;
- Set Up Time Reduction;
- 5s;
- Standardized Work;
- Productive Maintenance; and
- Error Proofing.
Six Sigma focuses on reducing process variation and enhancing process control using
- Statistical Analyses;
- Design Experiments; and
- Hypothesis Testing.
Why You Won't Find Better Lean Six Sigma Continuous Improvement Consultants
Experience is the key to success in any endeavor including Continuous Improvement. We are experienced engineers with decades of experience with Continuous Improvement in manufacturing environments with the responsibility of keeping lines running. We know how to implement Continuous Improvement without being disruptive.
We're led by a professional engineer with Lean Six Sigma Black Belt Certification. Black Belt Certification requires proven proficiency with the necessary tools and proven practical experience.
We're business people with top management experience. We
- know how Continuous Improvement integrates with the budget and overall strategic plan;
- understand all functional areas of a company and how the benefits from Continuous Improvement can benefit other areas; and
- how to communicate benefits to top management and other stakeholders.
Contact Us Online or Call Us at 610-914-1356 today.
Lisa Peterson, Ph.D., PE, MBA is the President of Pennsylvania-based Aftan Engineering. Lisa is a uniquely qualified professional Sustainability, ISO 14001, and Continuous Process Improvement Consultant with a Ph.D. in Environmental Engineering, a Lean Six Sigma Black Belt Certification, 30 years' engineering experience, and has held high-level management positions. Read Lisa's Resume.
SpeedPro Innovations
Reading, PA 04/30/20
Note: Aftan goes far beyond your expectations from a Continuous Process Improvement Consultant because they're more than "idea people". SpeedPro Innovations is a perfect example. Here's why.
Lauren invited Aftan to observe her operations for a few hours. Aftan had ideas for improvements and quickly developed conceptual designs and shared them with Lauren. The final design involved some metal machined parts, 3d Printed parts, and electronics. Aftan had all the necessary engineering skills and resources in-house and single-handedly did all the
- design work;
- drawings;
- machining in their own shop;
- 3d Printing of custom parts;
- assembly; and
- lastly, installation.
From this thought process, an approach of having backup plans is key to the success of the problem. This technique has allowed her success where others fail.
Lisa has instilled in me values and techniques by leading by example. Her drive and resolve are hard to keep up with. She is a role model for others to follow.
Lisa’s ethics are second to none often putting in more work and time than her peers. She knows hard work is the key to success. She knows her resources to help her accomplish tasks in a timely manner. Obstacles are not an issue and are deemed part of the solution process. Rather than let these get in the way, Lisa leverages them to find multiple solutions to the problem.
From this thought process, an approach of having backup plans is key to the success of the problem. This technique has allowed her success where others fail.
Lisa has instilled in me values and techniques by leading by example. Her drive and resolve are hard to keep up with. She is a role model for others to follow.
Lisa’s ethics are second to none often putting in more work and time than her peers. She knows hard work is the key to success."
Mark H., Engineering and Production Manager
Sinking Spring, PA 04/14/19