Tag Archives: Machining

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.

The Growing Medical Manufacturing Industry

The medical manufacturing industry is rapidly becoming one of the fastest growing industries in the world.  As the population continues to age, many resources are being put towards developing new medical devices that can be used to treat these patients.

Medical Manufacturing

From 2015 to 2020, the growth of the technical medical device market is expected to grow at compound annual growth rate (CAGR) of 5.5%. This translates to an equivalent of $428,970,000 USD. Several factors are contributing to this growth, such as technological advances, chronic disease, an aging population that is growing, and a rise in disability adjusted life years (DALYs).

Overall, there are 10 types of medical devices that are distinguished by type and/or region.

These include:

  • In vitro diagnostics (IVD)
  • Diagnostic imaging devices
  • Cardiology devices
  • Orthopedic devices
  • Endoscopy devices
  • Ophthalmology devices
  • Orthopedic devices
  • Diabetes care devices
  • Anesthesia/respiratory care devices
  • Kidney/dialysis devices

The largest share of the global market comes from North America, followed by Europe and Asia-Pacific. Due to easy access of advanced medical devices and established channels of distribution, the U.S. is currently the top market. However, with a rapidly growing region, Asia-Pacific is being driven by a large population and increasing health care needs in their healthcare infrastructure which is constantly improving.

At Tella Tool, engineering support is offered to aide in design for manufacturability for new projects and ideas. We offer high/low volume precision metal stampings, assemblies, fabricating, and CNC machining solutions. Our precise and quality work is well suited for most industries, including the rapidly growing medical manufacturing industry.

Tella Tool is committed to helping customers find the perfect solution for their needs, whether for the medical manufacturing market or any other industry. At Tella Tool we believe in supporting our customers fully – providing innovative engineering support, reliable product quality, and responsive customer service to our entire growing customer base. Contact us here for more information.

Tella Tool Has a New ERP System

As technology improves, companies must adapt to stay current with the times, and take advantage of new ideas and solutions that will improve their business.  Here at Tella Tool we have recently taken the step of adding a new ERP system from Plex which will give us a single platform for all of our ERP operations.

ERP stands for Enterprise Resource Planning, and is a business process management software that allows a company to integrate back office functions related to technology, sales and human resources.  At Tella Tool, we chose a cloud based ERP system so we would have a system that is accessible to us anywhere in the world at any time.   The centralized service and infrastructure saves us from having to host the system on internal servers which we would have to maintain, and allows for regular updates for security and maintenance purposes.

One of the biggest advantages of implementing this new system was the ability to have customer interaction in real time.  We can now perform transparent EDI transactions with our customers in the new system without the need for any additional external software.  In our new ERP system, we also now have all the sales tracking software we need to track leads, and save and view our customer’s purchase history with us.  The security of our new system is top of the line, from ironclad firewalls to automated security sniffers that make sure our data and our clients data is always secure.

Our new ERP system also gives us the ability to collect and integrate plant floor data including up time and downtime in one easy system.  We can also monitor efficiencies and keep track of inventory easily with it.  With the Manufacturing Execution System (MES) built into the ERP system, we can now connect every machine, device or console on the plant floor to the system, forming a cloud-based backbone that removes the need for third-party software and allows for new features and functions to be rolled out which keeps both Tella Tool and its customers on the leading edge of technology.

As a leading custom job shop, with state of the art capabilities for tooling, stamping, fabricating and machining, moving to a new ERP system with Plex is the next step in providing excellent service for our customers.  For the latest company news and updates follow us on Twitter and LinkedIn.

Manufacturing capabilities

Fotosearch_k11353134TELLA TOOL & MFG. CO., is located in Lombard, and it is one of the companies that is continuously growing and progressing. Its total dedication to quality and personal interest in servicing the needs of the customers has earned a reputation of being one of the highest quality sources of precision metal products in the country.

Tella Tool is a leading custom job shop, which is equipped with the state-of the-art capabilities that include tooling. Tella Tool manufactures precision metal work for a wide variety of industries, including Aerospace, Telecommunications, Computer, and Automotive.

The following are the services offered by Tella Tool & Mfg.:

  • TOOL & DIE – They are involved in the designing and building of all the tooling and fixtures, from simple short-run dies to elaborate class AA progressive dies.
  • COMPLETE STAMPING LINE – They offer punch presses from 10 to 1000 tons.
  • MACHINING DEPT. – They are involved in CNC Machining Centers and CNC Turning Centers for both short-run and long-run orders.
  • SHEET METAL FABRICATIONS – They offer shearing, punching, (including 8 N.C. presses and one 2600 watt laser machine) drilling, forming, welding (conventional and robotics), grinding/polishing, and assembly depts.
  • MODEL SHOP – Prototypes are always welcome.

The Lombard facilities incorporate over 110,000 square feet with more than $25,000,000 in state of the art precision equipment to meet or exceed the needs of the customer and to deliver quality products which are expected by the customer. In addition, Tella has a 50,000 square foot facility in Brownsville. This facility, encompassing metal stampings utilizing presses up to 600 tons and maintains service for South and Southwest customers. This facility operates with Engineering and Management support from TELLA TOOL & MFG. CO., Lombard, IL.