Lean Manufacturing and Six Sigma

As business and manufacturing has changed over the years, a greater focus has been made by companies to do a better job eliminating waste and redundant processes that are adding cost and slowing down production.  This business methodology is known as lean manufacturing, and it is a systematic method for eliminating waste within a manufacturing system.  At Tella Tool, as a leading custom job shop, with state-of-the-art capabilities, we have been taking steps to implement lean manufacturing as well as Six Sigma.

Six Sigma is a data-driven approach and methodology for eliminating defects in the manufacturing process.   It works by identifying and removing the defects in the manufacturing process, as well as by minimizing the variables that exist in the process that can lead to process delays, and additional costs and expenses.  Developed by great thinkers like Bill Smith, Mikel Harry, Shingo and Taguchi, it has a history of success in creating profitable and efficient companies.  The steps that make up the framework of Six Sigma are as follows:

D – Define

M – Measure

A – Analyze

D – Design

V – Verify

These steps are applied to improving any existing processes to “entitlement”, or perfection

At Tella Tool we have been working to implement the Six Sigma methodology to streamline our processes and make our business more efficient.  We started by reviewing our historical data, and then created a plan to collect baseline data that will be used to gage the project’s success.  An overview of process mapping, data types, operational definitions and measurement system analysis was worked on to create a foundation to work with.  A process map was created which was verified by walking through the process on the manufacturing floor, also known as GEMBA.  By walking the floor and observing the processes in action, many ideas were conceived and additions were made to our lessons learned log.  We also have learned the importance of operational definitions and data collection plans, which have helped to uncover many unknowns that would have created trouble late in the collection phase, rather than now when it is easy to change in the planning stage.

While changes to implement lean manufacturing and Six Sigma are ongoing, the benefits to our long term business will be immense.  To learn more about our manufacturing process improvements, and about capabilities, contact us here.

Tella Tool’s Prototype Capabilities

At Tella Tool & Manufacturing Company we are an industry leader in the metal stamping & assembly, fabrication and CNC machining business.  Currently we occupy 150,000 sq. ft. in 4 plants and 2 states, with over 125 employees providing metal forming and machining services to numerous industries.  We also offer full prototype capabilities, with quick turnaround service.  One industry that has taken advantage of this is the medical device manufacturing industry.

Prototypes are an essential component in the development of metal stampings, and fabricated and machined components.  They can save time and costs by detecting issues during the design phase, instead of after a full production run is completed.  At Tella Tool we have the resources and equipment to offer complete engineering support to develop prototypes of our customer’s concepts and designs.

Our prototype capabilities include the following equipment:

  • 3 Axis Laser
  • Vertical & Horizontal CNC machining
  • Press Brakes
  • Turret Presses
  • Mig, TIG and Spot Welding
  • Shear
  • Secondary punch presses

Our experienced, diverse and innovative Engineering team lends support, assistance and guidance through the entire product development process.  Our Engineers work hand-in-hand with our customers’ engineers to collaborate and ensure maximum efficiency and effectiveness through the design and prove out phases of a program.

Along with our prototype capabilities, we also offer program management resources which are dedicated to transforming the customer’s vision and expectations into an executable plan.  Our capabilities and experience allow us to streamline the delivery process, control costs and improve project results.  We will align our project management strategies directly with our customer’s business goals and objectives to make sure we meet their needs and expectations.

For more information regarding our prototype capabilities, as well as our other services and capabilities, visit our website or contact us here.  For the latest company news and updates, be sure to follow us on Twitter and LinkedIn.