Synchronous Management believes in a no-nonsense approach to delivering quantifiable results; we don't leave until the job is done. The following are typical of the financial benefits we have delivered:
Assembly Floor Cells and Visual Flow Controlsfor a $150MM per year East Coast high-tech electronics systems manufacturer. Results: Floor space reduced 40%; inventory reduced 70%.
Auto-Pull Kanban Systemfor a $60MM per year Massachusetts electro-optical manufacturer. Results: inventories down 60%; assembly stockouts eliminated; on-time delivery up 30%..
Capital Equipment Analysis and Justificationfor an $8MM per year New Hampshire contract circuit board assembly operation. Results: Sales up 10%; net profit up 80%.
Cellular Arrangement and Supplier Pull Systemfor a $20MM per year Massachusetts medical equipment manufacturer. Results: Floor space down 60%; inventory down 40%.
Cellular Layout, Supplier Pull and Auto-Pull Kanban Systemfor a $100MM per year Minnesota manufacturer of weight training equipment. Result: Inventories down 40%; assembly shortages eliminated.
Cellular Layout and Pull Systemfor a $30MM per year New Hampshire printing equipment manufacturer. Results: Floor space down 50%; inventory down 60%.
Cellular Manufacturingin a $3MM per year Massachusetts cable assembly plant. Results: Floor space required down 80%; labor cost down 30%; sales up 300%.
Cellular Manufacturing/Group Technologyin the machine shop of a $90MM per year Massachusetts industrial goods manufacturer. Results: Manufacturing lead times and WIP down 80%.
Cellularization and Internal/Supplier Pull Systemsfor a $30MM per year Massachusetts laser manufacturer. Results: Floor space reduced 60%; total inventory reduced 65%.
Continuous Process Flow controlsystem for a $20MM per year jet engine repair facility. Results: Average turnaround time reduced by 40%; maximum reduced by 70%.
Distribution Planning and Controlsystem for a $100MM per year European industrial and consumer goods manufacturer. Results: Finished goods down 35%; customer service up 90%.
Inter-Plant Pull Signalsfor the movement of work in process among four plants of an international industrial goods manufacturer. Results: 90% reduction in assembly stockouts.
Internal and Supplier Pull Signalson over 1200 parts for a $500MM per year New England aerospace manufacturer. Results: Inventories down an average of 40%; internal on-time delivery to 98%.
Make-To-Order and Repetitive Pull Signalssystem for a $20MM per year California aerospace fabricator facing a turnaround situation. Results: WIP down 80%; shipments up 20%.
Make-To-Order Kanbansplant-wide in a 600-man Connecticut engineering prototype shop, including training of organized direct labor personnel. Results: Lead time down 50%; work/wait ratio up 80%.
Make-To-Order Pull Systemfor a $6MM per year Connecticut aerospace machining job shop. Resulsts: work in process and lead times down 50%; customer service up 30%.
New Plant Layout and Automated Pull Systemfor a vertically integrated $120MM per year Wisconsin construction capital equipment manufacturer. Results: Savings of over $1MM in new construction costs; inventory down 40%; assembly shortages down 90%.
Non-Repetitive Pull System & Changeover Reductionfor a $2.5MM per year Connecticut CNC turning and milling job shop. Results: Inventory down 50%; defects down 90%; sales per employee up 60%.
Partnership Purchasingagreements between a New Hampshire sheet metal fabrication company and its vendors. Results: Purchased inventory down 70%; purchased cost down 7%.
Past Due Reductionfor a $30MM per year Maine producer of pneumatic regulation and lubrication equipment. Results: Past due customer backlog down 90%.
Production Equals Salesdemand-driven manufacturing system for a $70MM per year Connecticut ball bearing manufacturer. Results: WIP, finished goods & distribution inventories down 65%; fill rates at 95%+.
Repetitive Pull Signalsfor a $1MM per year Vermont hand tool manufacturer. Results: Inventory down 50%; customer fill rates up 80%, sales up 100%; net profit up 600%.
Repetitive Pull Signals and Changeover Reductionfor a $6MM per year Massachusetts extrusion and machining job shop. Results: Changeovers down 95%; lead times down 50%; sales up 600%.
Repetitive Pull Systemfor coil steel suppliers and sheet metal shearing operation for a $100MM per year Chicago bottle and jar enclosure producer. Results: Inventory down 50%; stockouts down 90%.
Repetitive Pull Systemfor a $30MM per year Ohio plastic tubing extrusion and winding company. Results: Inventory down 60%; service up 30%.
Repetitive Pull Systemsfor a $20MM per year New York aftermarket marine accessories manufacturer. Results: Inventory down 60%; customer service fill rates to 98%+.
Team Qualityprogram in a medium-sized Virginia electronics manufacturer. Results: Defects down 80%; QC down from ten inspectors to two auditors.
Virtual Pull Systems to control manufacturing and distribution for a $3.5 Billion per year midwest consumer packaging producer. Results: Inventory down 25% to record lows; fill rates to record high of 99.7%.