Product category:
Casting and Forging Subcontracting Services
News Release from: Doncasters Group | Subject: Lean manufacturing
Edited by the Manufacturingtalk Editorial
Team on 08 June 2007
Lean manufacturing with six sigma and
Kaiken
A series of lean manufacturing projects resulted in financial savings of more than GBP200,000 in a year for Ross and Catherall following adoption of the Doncasters' Lean Sigma Charter.
Ross and Catherall, the Sheffield-based manufacturer of high-performance alloys for demanding commercial and industrial applications such as aerospace and industrial gas turbines, is celebrating after a series of lean manufacturing projects resulted in financial savings of more than GBP200,000 during 2006 Lean initiatives undertaken during the period included projects to increase yield and reduce downtime on furnaces, along with energy improvements as part of the firm's ISO14001 environmental management system
This article was originally published on Manufacturingtalk on 5 May 2003 at 8.00am (UK)
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Part of the global engineering Doncasters Group, Ross and Catherall has fully adopted the Doncasters' Lean Sigma Charter - a company-wide commitment to a culture of continuous improvement via lean manufacturing and Kaizen principles.
This commitment to lean manufacturing has been instrumental in the recent success of the Doncasters Group in what is an increasingly competitive market.
The sustained programme of lean manufacturing projects and Kaizen training at Ross and Catherall includes initiatives to improve efficiency from shop floor processes through to back office functions.
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For example, the site recently completed a project to reduce method-of-manufacturing times, drive out non value-added steps and better control the manufacturing process, using six sigma disciplines.
The result? Significant annual processing savings of over GBP50,000 for energy expenditure and GBP75,000 in labour costs, as well as the creation of additional melting capacity through time saved.
Eric J Lewis, CEO of the Doncasters Group, said: "A continuous improvement culture is essential in today's manufacturing climate.
UK manufacturers must build their entire business model around lean operating effectiveness and a cradle-to-grave approach covering all functions, from new product introduction, supply chain and manufacturing through to administration and distribution.
"At Doncasters, we never take success for granted and are continually searching for better ways to deliver results for our clients.
The series of lean manufacturing projects at our Ross and Catherall business just goes to show what can be achieved by commitment to lean principles." Kaizen, the Japanese management philosophy of continuous improvement, is based around the Six Sigma model that measures levels of perfection in the production process.
This enables companies to highlight and work to correct any weak points.
The higher the Sigma, the closer to perfection the process is, with Six Sigma indicating a near prefect production process.
Those beginning their Kaizen training are known as Green Belts while expert Kaizen Black Belts lead Six Sigma teams.
Doncasters' Ross and Catherall site has one designated Kaizen Black Belt and has trained over 21 Green Belts.
Ten employees are also NVQ candidates on business improvement techniques.
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