Innovation and transformation are at the heart of AJW-L960’s recent journey toward process excellence. Leveraging Lean principles, Theory of Constraints methodologies, and Six Sigma techniques, the organization has embarked on a mission to eliminate waste, enhance quality throughput, and meet customer demands more effectively than ever before.
Under the guidance of forward-thinking leadership, AJW-L960 has empowered its team to challenge existing processes continually. This proactive approach has led to a series of groundbreaking process improvement events, revolutionizing how assets are processed within the organization. By challenging decades-old methods, the team has ushered in a new era of efficiency and productivity.
A standout example of this commitment to improvement lies in the transformation of the Paint Shop. By applying Lean Principles and identifying Eight Forms of Waste, the shop identified opportunities for innovation in fixturing, drastically reducing processing times over 45 days to an average of 10 days or less. This remarkable achievement has had a profound impact across multiple product lines, eliminating backorders and enhancing delivery reliability.
"You WILL fail, just remember that failure is just one avenue that you now know doesn’t work. Learn from it and move on to the next idea." — Steve Roesslein, Fiberglass Technician
Central to AJW-L960’s success has been the implementation of new tools for tracking work processes and performance metrics. The introduction of a JIRA Production Tracking Tool and KANBAN Board for Maintenance Repair and Overhaul (MRO) Planning and Scheduling has provided unprecedented visibility into operations, facilitating better decision-making and resource allocation.
Furthermore, the organization has prioritized standardization through repeatable processes and collaborative creation of Standard Work procedures. This approach ensures consistency, accelerates onboarding of new employees, and fosters a culture of continuous improvement.
"Moving from a ’cradle to grave’ process (where one person works one part from start to finish) to a gated flow has helped our efficiency double if not more than I have seen in my 30 years in this shop." — Keith Cummings, Paint Tech
Recognizing the importance of customer feedback, AJW-L960 has taken decisive action to address past challenges. By enhancing communication, improving service offerings, and streamlining processes, the organization has transformed customer perceptions, earning praise for reliability, responsiveness, and quality.
The results speak for themselves. Through strategic initiatives and a relentless focus on improvement, AJW-L960 has achieved remarkable outcomes. Shop order durations have plummeted from an average of 180 days to just 14 days, while cycle times have been slashed, enabling greater flexibility and responsiveness to customer needs.
Looking ahead, AJW-L960 is poised to solidify its position as a preferred provider of fabrication and paint refurbishment services. With a commitment to innovation, efficiency, and customer satisfaction, the organization is painting a new course for success in the realm of Metals Technology.
"I have been on a couple of Continuous Process Improvement (CPI) projects now, and one thing you have to understand is that it NEVER ends. Being able to understand the ’Continuous’ part of Continuous Process Improvement is the key. There is no one set thing that is going to be a cure all for any shop, but if you keep yourself fluid and able to adjust to any situation you can overcome any obstacle you encounter. The process belongs to you. If it needs to be changed then just change it. It will only be as successful as you make it." — John Teas, Shop Lead
AJW-L960’s journey exemplifies the transformative power of continuous improvement and strategic innovation. By embracing Lean principles, leveraging cutting-edge methodologies, and prioritizing customer satisfaction, the organization has not only overcome past challenges but has also emerged as a beacon of excellence in the field of Metals Technology.
