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Are you a job shop, custom manufacturer, production operation, or service organization? Insyte Consulting can help you make significant improvements to your operations through the application of lean manufacturing tools. Up to 95% of a product’s lead time can be composed of non-value added time. Lean manufacturing is a systematic approach to identify, prioritize and eliminate non-value time and money wasting activities.

Typical Results of a Lean Project

90% Reduction in lead-time
50% Increase in productivity
85% Reduction in work-in-process inventory
85% Improvement in quality
75% Improvement in space utilization

Overproduction
Waiting time
Defects
Transportation
Non-value processing
Underutilized talents
Excess inventory
Excess motion

Eliminate Non-value Activities

Overproduction
Waiting time
Defects
Transportation
Non-value processing
Underutilized talents
Excess inventory
Excess motion

Systematic Approach

Our approach to achieving fast, significant and lasting improvements is to map a company’s unique operations process to identify and prioritize issues. Working with company personnel, we selectively utilize lean tools appropriate to addressing the identified issues. Results are quick and measurable. Tools may include:

Value Stream Mapping
Facility Layout
Visual Guides
5S Workplace Organization
Standardized Work
Teams
Batch Reduction
Quality at Source
Point of Use Storage
Quick Changeover
Total Productive Maintenance
Cellular and other Flow Techniques
Pull/Kanban
Kaizen Events

Our Experience and Track Record

Insyte Consulting has Western New York's largest and most diverse staff of Lean Six Sigma manufacturing experts—all with extensive hands-on, industry experience. We have helped WNY companies improve operations using lean manufacturing methodologies for over ten years. Insyte has worked successfully with more WNY companies using these techniques than any other consulting organization. We welcome the opportunity to discuss your specific situation and how we may contribute to your improved competitiveness and profitability using proven lean manufacturing techniques.

“Insyte Consulting has enabled us to gain a competitive advantage within a very demanding market.” Kyle Swiat, Vice President, STI-CO Industries

“Insyte... they were able to effectively work with us to implement a lean manufacturing program that met our specific needs and contributed to the continued success of the business.” Tom Rybicki, Director Manufacturing, Polymer Conversions

“The expertise, outside resources and ideas that Insyte engineers bring to the Kaizen teams is invaluable...” Craig Stryker, Director Operations, Accellent, Inc.

House of Lean

The House of Lean has four main components as follows:

Value Stream Mapping serves as the entrance to the House of Lean. This tool provides a visual representation of production and support activities from receipt of order to shipment for both material and information flows. Most importantly this process subsequently provides the future state map of how value should flow.
Three key lean tools provide the foundation for the house of lean in all implementations. These tools include:
- 5S/Work Place Organization is a structured methodology consisting of sort, set to order, scrub/shine, standardize and sustain. This provides a safe, clean, neat organization for all required parts, tools and supplies, while removing anything that is not normally needed within the work area.
- Visual Controls are simple signals that provide an immediate understanding of a situation or condition. These are efficient, self-regulating and worker-managed.
- Plant Layout is the physical location of all work processes and activities.
Various other lean tools provide the building blocks for the House of Lean based on the input determined from the value stream mapping process.
Continuous Improvement is symbolized by the roof of the House of Lean. Since lean manufacturing is a process and not a program, it is never completed and further improvements can always be achieved.

Contact us at 716.636.3626 or info@insyte-consulting.com to discuss ways in which Insyte Consulting might help you make significant improvements to your operations through the application of lean manufacturing techniques.

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