Process + Manufacturing + Operations Evaluation & Optimization
This is where we stand out from other consulting firms: back-end strategy. We specialize in the optimization of complex processes, systems or organizations within your business; minimizing cost and maximizing throughput and efficiency. We eliminate waste of time, money, materials, man-hours, machine time, energy and other resources that do not generate value…
Manufacturing Systems Engineering
- Lean manufacturing and controlled flow production.
- Fixturing and tooling requirements for:
- Manufacturing process planning.
- Geometric dimensioning and tolerancing.
- Computer aided inspection.
- Cellular and flexible manufacturing.
- Facility layout.
- Electrical circuitry and its relationship to industrial control systems.
- Application of transducers in the form of sensors and actuators, with applications in manufacturing, distribution and mechanical systems.
- Programmable Logic Controllers (PLC) programming its use for automation solutions.
- Automated identification systems such as Radio Frequency Identification (RFID) and Bar Coding technologies.
Computer Aided Design and Manufacturing
- Parametric curves and surfaces and solid modeling.
- CAD software.
- CAD/CAM integration.
- Computer numerical control.
- CNC programming languages.
- Process planning.
Stochastic Modeling, Analysis and Simulation
- Developing and analyzing simulation models using a simulation language.
- Utilizing model output to make important business decisions.
- Fitting of data to statistical distributions.
- Markov processes and other queuing models.
- Application to various areas of manufacturing and service systems such as:
- Material handling.
- Customer queues.
Statistical Quality Assurance
Statistical methods for process improvement including:
- Simple quality assurance principles and tools.
- Measurement system precision and accuracy assessment.
- Control charts.
- Process capability assessment.
- Design and analysis for process improvement.
Engineering Economic Analysis
- Performing economic analysis of engineering decisions under uncertainty.
- Financial engineering basics including time value of money, cash flow estimation, and asset evaluation.
- Comparison of project alternatives accounting for taxation, depreciation inflation, and risk.
Designing and analyzing of production systems including:
- Inventory control.
- Material requirement planning.
- Project planning and scheduling.
- Operations scheduling.
- Other production systems such as Just-In-Time (JIT), warehousing, and global supply chains.
- Formulation of mathematical models for systems.
- Methods of improving search.
- Linear programming and sensitivity analysis.
- Network models.
- Integer programming.
Design & Analysis for System Improvements
Implement methods and strategies in the areas of lean system improvements including:
- Continuous improvement.
- Setup reduction.
- Workplace organization.
- Inventory and waste minimization.
- Analyze and quantify the impact of process changes.
System Design, Manufacturing Processes and Specifications
- Engineering drawings and specifications.
- Methods for designing and improving systems, applications, or quality issues related to machining processes.
Ergonomics and Work Design
- Analyzing the impact on worker and work place productivity, and cost.
- Investigating work physiology, biomechanics, anthropometry, work methods, and their measurement as they relate to the design of human-machine systems.
- Metal casting.
- Polymer processing.
- Powder metallurgy.
- Composites manufacturing.
Engineering Sales & Marketing
- Implementing sales automation technology.
- Market analysis and segmentation.
- Technical value propositions and competitive positioning.
- Developing pricing and distribution strategies.
- Developing sales teams and global sales plans.
- Evaluating organizational decision processes.
- Developing of technical sales strategies.
The program (or process) evaluation and review technique, PERT, is a statistical tool, used in project management, which was designed to analyze and represent the tasks involved in completing a given project.
Due to the critical nature of some project objectives, a small business implements controls to make sure projects are successfully completed. The Program Evaluation and Review Technique is a program network analysis method used to plan and control large projects, including performance improvement efforts.
PERT analysis improves planning and decision-making by integrating and presenting data from multiple departments. Gathering qualitative and quantitative data from multiple sources also helps coordinate project activities and improves communication among departments. PERT identifies responsible departments and each person’s project role. The visibility of areas of responsibility encourages management commitment to the project. In addition, PERT reveals activity inter-dependencies and contributes to the development of a master plan that provides a current view of business operations.
A time and motion study (or time-motion study) is a business efficiency technique combining the Time Study work of Frederick Winslow Taylor with the Motion Study work of Frank and Lillian Gilbreth. It is a major part of scientific management. After its first introduction, time study developed in the direction of establishing standard times, while motion study evolved into a technique for improving work methods. The two techniques became integrated and refined into a widely accepted method applicable to the improvement and upgrading of work systems. This integrated approach to work system improvement is known as methods engineering and it is applied today to industrial as well as service organizations, including banks, schools and hospitals.
Time study is a direct and continuous observation of a task, using a timekeeping device (e.g., decimal minute stopwatch, computer-assisted electronic stopwatch, and videotape camera) to record the time taken to accomplish a task and it is often used when:
- there are repetitive work cycles of short to long duration,
- wide variety of dissimilar work is performed, or
- process control elements constitute a part of the cycle.
The Industrial Engineering Terminology Standard, defines time study as “a work measurement technique consisting of careful time measurement of the task with a time measuring instrument, adjusted for any observed variance from normal effort or pace and to allow adequate time for such items as foreign elements, unavoidable or machine delays, rest to overcome fatigue, and personal needs.”
Gap analysis involves the comparison of actual performance with potential or desired performance. If your organization does not make the best use of current resources, or forgoes investment in capital or technology, it may produce or perform below its potential. Gap analysis identifies gaps between the optimized allocation and integration of the inputs (resources), and the current allocation-level. This may reveal areas that can be improved. Gap analysis involves determining, documenting, and approving the difference between business requirements and current capabilities. Gap analysis naturally flows from bench-marking and from other assessments. Once the general expectation of performance in an industry is understood, it is possible to compare that expectation with the company’s current level of performance. This comparison becomes the gap analysis. Such analysis can be performed at the strategic or at the operational level of an organization.
Gap analysis is a formal study of what a business is doing currently and where it wants to go in the future. It can be conducted, in different perspectives, as follows:
- Organization (e.g., Marketing)
- Business direction
- Business processes
- Information technology
Need a more efficient process? Let’s do an evaluation.