Humanetics is a world recognized manufacturer for a diverse group of industries including: cellular, telecom, satellite, communications, banking, printing, power supply, postal automation, airport automation, semi-conductor, ATM, defense, aerospace, computer, medical, and many others. Humanetics' South Texas facility was opened in November of 2003 in the city of McAllen, TX. This 100,000 sq. ft. facility has the capability to service all the metal fabrication needs of companies in this area. In addition, the ST facility has the ability to do mig, tig, and resistance welding with a wide array of materials.
Some metal fabrication processes at Humanetics were taking too long. “We knew there had to be a better way,” says Joe Haynes, Humanetics General Manager. The manufacturing process was moving in batches of 100 pcs from one department to another. This created a lot of inventory and lead time . For instance, one core process typically took 5 days to complete.
TMAC provided Lean training for 12 shop supervisors and managers, including Joe Haynes. “A lot of us grew up in the industry, but it was time to go back to school”. The participants learned how to use Value Stream Mapping, 5s, and Cell/Flow through simulations and on-site observations and changes. Part of the training focused on different production areas. Participants studied the movement of workers and materials through the manufacturing process, resulting in spaghetti diagrams that visually showed the movement. Haynes said the training made them look at cycle times and question why jobs get started and then sit for several days before completion of the next steps.
Lean Enterprise was well received by the staff, Haynes said. They took the risk of changing the way they used to work. After the training, managers and supervisors along with TMAC staff planned the new cell layout, assigned resources, made the appropriate changes, ran a pilot, trained operators, and started working in a better and more efficient way.
“The manufacturing cell, using single piece part flow, makes money. We have increased our throughput using fewer resources to accomplish the task. “
Lupe Quintanilla
Lean Champion
Humanetics
"We have increased our productivity on an average of 23% using Lean principles."
Joe Haynes
General Manager
Humanetics