Journey To Lean Manufacturing

Our Journey to Lean Manufacturing began in 1997, and has continually improved manufacturing and administration processes ever since. The entire team of DeWys Manufacturing realizes that LEAN Manufacturing is a never ending journey with small incremental improvements. We now maintain the right machines, the right people, and the right production processes, ensuring that the Lean Journey becomes an intrinsic part of our DNA. We include the Lean principles throughout all of our processes, from order entry through final shipping of a product. We will continue to enhance our Lean Manufacturing  processes to drive out unwanted costs for our customers.

Watch our Journey to Lean Video

Lean Tools Utilized at DeWys Manufacturing

6S – DeWys Manufacturing is Serious about Safety!

  • Safety
  • Sort
  • Scrub
  • Straighten
  • Standardize
  • Sustain

Continuous Improvement

  • Team member involvement through Think Sheet Process
  • Daily / weekly huddles
  • Layered Process Audits (LPA’s)
  • Certified Continuous Improvement Coordination

Kata

  • Understand the challenge
  • Grasp the current condition
  • Establish your next target condition
  • Experiment towards that target condition (PDCA)

Innovation Team

  • Work as a team to bring our continuous improvement process and projects to the next level
  • Improve our processes from the front door to the back door
  • Automate, Automate, Automate!
  • Reward innovation ideas from team members

Identification & Reduction of the Eight Deadly Wastes

  • Product Defects
  • Waiting
  • Excess Motion
  • Inventory
  • Unnecessary Processing
  • Over Production
  • Excess Transportation
  • Under-Utilizing Team Members

Kan Ban

  • Steel, fasteners, powder, corrugated, and point-of-use at value streams

Point of Use

  • Shadow Boards (Tooling at the machines)
  • Made to stock in the value streams
  • Quality measuring equipment at the machines

Preventative & Predictive Measures

  • Daily / weekly / monthly process
  • Electronic reminder system

Pull Systems

  • Build only when necessary
  • Downstream customer drives demand

Standard Work

  • Manufacturing the product right the first time

Value Stream Mapping

  • Map every step of a process
  • Eliminate wasted steps and time
  • Remap and analyze again

Visual Management

  • Value Stream Scoreboards
  • Everything in its place
  • Process is clearly seen