Journey To Lean Manufacturing

Our Journey to Lean Manufacturing began in 1997, and has continually improved manufacturing and administration processes ever since. As part of continuous improvement, DeWys Mfg. implemented Operational Excellence processes and training’s in the beginning of 2018. Team members at DeWys Manufacturing value that Lean Manufacturing is a never-ending journey with small incremental improvements. This process involves focusing on the customer needs, empowering team members to continually improve the company through small incremental projects.

By integrating the process into our Lean Journey, DeWys Manufacturing continues to improve culture and performance providing long term sustainable growth.

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


  • 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