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Case Study: Lean Deployment Project

Faced with the challenge of introducing ten new products to an existing production line, our client, a leading medical devices company, had initially devised a process using a total of 296 tooling items.

To significantly reduce costs and sustain competitive advantage, it was evident that a new approach was needed and the client looked to OSTC for a solution.

Using our Lean expertise and innovative design capability, our team mapped the process to identify where waste could be eliminated and a streamlined production flow designed. We reduced the number of tooling items from 296 to 120 – achieving efficiencies of more than 40%.

The improvements achieved are effectively demonstrated in the Before and After illustrations below.

The results achieved in the rationalization of their manufacturing processes enabled our client to increase productivity, reduce lead-time and achieve very significant cost savings.

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