The projects and accomplishments
listed here are specific to Ken Branco, founder and principal
of R.E.V.V. International. All other members of the association
have similar experiences. Listings and references are available
Project: Consortium of metal manufacturing companies. Wide variety of
products and operations. Develop and deliver unique Certified
Lean Expert Program.
Actions: Design and develop ?from scratch?
Expert development program consisting of Leadership training,
15 classroom days, multiple cross-company Kaizens, internal
projects, certification criteria, and more.
Results: Delivered on time and in budget. Of
20 original candidates, 12 were Certified by meeting or exceeding
stringent requirements of the program. See 'Programs.'
Project: Consortium of metal manufacturing
companies. Wide variety of products. Design and deliver Kaizen-based
Lean Implementation Strategy.
Actions: Using the full resources of R.E.V.V.,
planned and executed a series of 32 Kaizen events across seven
companies, on time and in budget.
Results: Return on total investment of more
than 150% during the engagement. Equivalent savings to continue
indefinitely. Sample results within companies. Product travel
reduced 25+%, space requirements reduced 25%+, work in process
reduced 35%, setup times reduced 50+%, output increased 25%
(no increase in personnel), etc.
Project: Statewide business and industry association.
Co-develop unique 'group consulting' programs to assist multiple
companies a lowered cost.
Actions: As a joint venture, developed and
delivered (to ~20 companies) group consulting programs for Lean
development, shop floor and office.
Results: All companies had returns on investment
of more than 200%. Forty percent of companies participated in
multiple programs. Ninety percent of clients said program 'exceeded
expectations.' R.E.V.V. received 2002 Connecticut Innovation
Award for this work. See 'Awards and Press.'
Project: Lightning equipment manufacturer,
ship from stock. Relayout shop floor for flow, determine strategic
inventory, redesign office information flow.
Actions: Collaborated with leadership to completely
revamp layout. Developed strategic inventory levels on a part-by-part
basis. Redesigned the pick-pack-ship process. Mapped and redesigned
Results: Space requirements reduced by 25%.
Productivity increased by 25%. Stockouts reduced significantly.
Office process steps reduced by ~35%.
Project: Fortune 200 manufacturer of pharmaceuticals.
World-wide operations. Led 5-day Overall Equipment Effectiveness
(OEE) Kaizen in Australia.
Actions: Developed data requirements, trained
and led cross-functional team of ten in Kaizen to improve output
and OEE of automated Blow-Fill-Seal line.
Results: In 90 days, OEE (a measurement of
effectiveness) doubled, and output of the line doubled.
Project: Manufacturer of linear actuators.
Make to stock, make to order. Industrial and Military applications.
Perform Setup Reduction Kaizens.
Actions: Trained teams and led five setup reduction
Kaizens. Mentored leadership in the tools and techniques.
Results: Setups reduced by 55-65%. Shop able
to produce equal output with 10% less man-hours. Flexibility
increased, lead times reduced (anecdotal data).
Project: Fortune 200 diversified manufacturer.
Jet engines to spark plugs. Lead four week of Lean training
for Lean Expert Candidates.
Actions: As wave leader, responsible for development
and delivery of deep Lean training. Developed learning environment,
kept agenda, mentored candidates on a one-to one basis.
Results: Most highly rated instructor in the
history of the program. Ratings (both technical and leadership)
averaged 4.4 of 5.0.
Project: Manufacturer of scientific and pharmaceutical
glass. Perform multiple Baseline Kaizens to determine Lean potential
and prioritize projects.
Actions: Trained teams of 20+ individuals in
Lean and Baseline tools. Co-led one-week Baseline Kaizens in
scientific and pharmaceutical Value Streams.
Results: Baselines identified more than $10
million in opportunity. Projects prioritized, planned, scheduled
Project: Semi-custom kitchen manufacturer.
Complete transition of shop floor operations from batch, queue,
and assemble to 'one kitchen flow.'
Actions: Collaborated with leadership to develop
shop philosophy, total shop layout, plan and execute transition
to one kitchen flow.
Results: Shop floor lead time reduced 55% (11
days to 5), work in process reduced 80%, productivity (hours/cabinet)
Project: Manufacturer of architectural hardware.
Make to stock, short delivery. Train and facilitate New Product
Introduction teams to reduce lead times, improve quality and
participation, move decision making outward.
Actions: Collaborate with leadership to determine
strategic intent. Train NPI teams in process, decision making,
and interpersonal skills. Facilitate process.
Results: New products to market on time. Process
simplified, decisions moved outward. Client referred to rollout
as "possibly the best introduction in the history of the
Project: Manufacturer of precision gears, make
to order. Perform Setup Reduction Kaizens, map and redesign
office information flow.
Actions: Led several setup reduction teams
over a period of 18 months. Mapped and redesigned office flow
to reduce lead time, improve responsiveness.
Results: Setup times reduced 50-65%. Many setups
now under Takt time, resulting in 'transparent' change from
part to part. Office lead time reduced ~30%.
Project: Manufacturer of wire products. Make
to order. Reduce lead time and batch quantities in the shop.
Actions: Trained and led team through process
improvement for lean. Mapped, analyzed, redesigned and implemented
new system for scheduling and manufacturing.
Results: Product travel reduced by 90%, batch
size reduced by 50%. Lead time reduced by 50%. Work in process
reduced by 75%.
Project: Manufacturer of automotive initiating
devices. Make to Kanban, missed deliveries carry stiff penalty.
Actions: Trained teams and led four shop floor
improvement Kaizens, covering multiple product lines. Identified
and removed constraints, improved flow.
Results: Improvement from 'hand to mouth' Kanban
replenishment to one week of strategic inventory (required)
within six weeks. Output of a single line increased by 25%.
R.E.V.V. International is relentlessly
focused on skill and knowledge transfer, to speed your journey
toward the Vigorous (Lean) Enterprise. We have ready access
to more than a dozen world-class consultant/trainers, each with
many years of experience and deep skills (see ‘Friends
of R.E.V.V.’). The composition
of this team has been developed to be able to provide the right
skills, to the right depth, just in time.