Realized a 300% increase in labor productivity in their exterior cladding (siding) station

Cutting Edge is a small, custom modular home builder serving the Bay area of California.

They struggled with defining their process, tracking productivity, and instituting standard operating procedures. As a result, their throughput had been very low and unpredictable. They joined our Lean Offsite™ program with the goal of optimizing their manufacturing process, increasing throughput, and improving their productivity.

Results

We started off by helping the client get their factory organized, which dramatically improved their efficiency and reduced process waste immediately. Then, in month 2 of the program, we helped them develop and implement several key measures to reduce waste in their most problematic stations, including Siding. Within 2 weeks of implementing the measures, they reported that their cycle time for siding a complete module had decreased from 3 full days to only 1, a 300% improvement.