ASI Technologies, Inc. has recently implemented additional lean manufacturing into its manufacturing practices by imbedding 5S methodologies across the manufacturing floor. These changes will appreciably increase production efficiency, curtail waste, and reduce cost, which will benefit both our customers and associates.

"When combined with the single piece flow methods introduced some years ago and now designed into all new product launches, it will provide the most bang for our buck, and since these efforts are directly envisioned and implemented by the associates, there is immediate buy-in and increased expectations of success." said Clay Lepley, ASI's Production Manager and leader in this effort.

Storage bins for parts

According to the EPA, "Lean manufacturing is a business model ... that emphasize(s) eliminating non-value added activities while delivering quality products on time at least cost with greater efficiency." Put simply, it is a more economical and efficient way of manufacturing products, which is essential in today's global market and challenging economy.

"It eliminates wasting time," said Stephon Gunter, one of ASI's assembly line leaders. "It is an organized process to increase production."

Standard work instruction for one step of a process

Initial lean manufacturing was implemented with the assistance of Delaware Valley Industrial Resource Center (DVIRC), a company that specializes in assisting small and medium manufacturing businesses. They again provided assistance and training to kick off the 5S efforts that are underway at ASI.

"ASI, as a company, has really bought into DVIRC's message, and is spending the resources necessary to improve our processes," Lepley said.

ASI's goal is to have teams continually evaluating and improving all aspects of their manufacturing and storage processes.

Although only four 5S events have been completed since the training earlier this year, the plant is already showing signs of improved organization. Color coded bins, tool storage peg boards, and standard work instructions have all been installed. Another 5S team will launch in the upcoming weeks.

Associates building Viking transaxles

Gunter says that lean manufacturing has "improved the work flow" of the assembly line.

"Everybody knows what they've got to do," he said.

Another change came when ASI replaced old metal carts used to transport cut gears with brand new hydraulic lift tables for better ergonomics. The carts are easier to push and reduce bending and lifting that the associates had to do previously.

New hydraulic lift carts for gear storage

Lean manufacturing also benefits ASI's customers. Lepley notes that since they are now producing products more efficiently, there are fewer problems on the assembly line.

"[Lean manufacturing] translates directly into a lower reject rate," he said.

The biggest difference in the plant since 2011 is a smoother flow and rate of production, which eliminates risk-prone rushing by the associates. There is also a sharp reduction in over-time required to get the products out on time.