Eagle Group Blog | Lean Manufacturing

    Stories from the Lean Manufacturing Journey

    Posted by Vikki Shonkwiler on 2018 Jul 2

    Eagle Alloy has been practicing lean manufacturing for close to a decade. Beyond the benefits to productivity and efficiency imparted by lean tools, Eagle companies have come to see lean manufacturing as part of their company culture. The inclusiveness, creativity and quality improvement they’ve been able to foster has paid off dividends, both in workplace atmosphere and customer retention.

    Lean implementation makes a more dependable supplier

    Almost all the way back at the beginning of Eagle Alloy’s lean journey, about six months into their implementation of cellular manufacturing, the company was already seeing a noticeable productivity boost. They came into contact with a potential customer—we’ll call them Company A—who scheduled a shop tour at Eagle Alloy. Company A was already a successful manufacturer, but their casting supplier had recently gone bankrupt and they were looking for a replacement.

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    Tags: Lean Manufacturing, Efficiency, Company Culture

    Infographic: Lean Manufacturing Timeline

    Posted by Jeff Cook on 2018 May 22

    The history of lean manufacturing dates back at least to the 1700s, when Eli Whitney developed interchangeable parts in order to deliver a massive order of muskets to the American Army.

    It wasn't until 1988 that John Krafcik coined the phrase "lean manufacturing" in his research as an MIT student. For most of the 20th century, lean manufacturing was tied closely to industrial innovations in the United States and Japan. While it wasn't called "lean" for many decades, American and Japanese automakers laid the groundwork for the tools of lean manufacturing that we use today.

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    Tags: Lean Manufacturing, Manufacturing, Efficiency

    Case Study: Lean Manufacturing at Eagle Alloy

    Posted by Jeff Cook on 2018 Mar 27

    Eagle Alloy, Inc. was founded in 1979 and quickly grew from a short-run facility to a medium-to-high-production steel foundry. Despite the company’s success, its founders were not satisfied with the status quo. Having heard of developments in lean manufacturing, they decided to implement these tools in hopes of achieving greater efficiency, stability and quality throughout the production process.

    5S: The Beginning

    As with many production facilities beginning to experiment with lean manufacturing, Eagle Alloy started with 5S. 5S is easy to adapt to just about any environment, and the key to lean is customization. Every lean tool must be adapted to the particular type of production, to the size of the company and to the facility's space.

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    Tags: Lean Manufacturing, Eagle Alloy, Case Study

    5 Lean Manufacturing Tools You Should Already Be Using

    Posted by Jeff Cook on 2018 Feb 7

    Lean Manufacturing principles encourage maximum efficiency for just about any production facility. Lean Manufacturing is also more of a necessity than ever, with cutthroat competition across the manufacturing industry forcing all players to up their efficiency levels.

    If you're worried that your company isn't lean enough, take a look at these five tools from the Lean Manufacturing playbook.

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    Tags: Lean Manufacturing, Manufacturing, Efficiency, Productivity

    What Is Lean Manufacturing?

    Posted by Jeff Cook on 2018 Jan 24

    Lean manufacturing helps manufacturers improve efficiency by eliminating waste in the production process, but what exactly is lean manufacturing? Is it a product, a procedure, a religion?

    None of the above. Lean manufacturing is an adaptable set of “tools” that can be applied to any system of manufacturing–whether that system produces spring coils, jet engines or blog posts. It starts with identifying waste in a production process, and then focuses on eliminating that waste bit by bit until production is as streamlined and efficient as possible.

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    Tags: Lean Manufacturing, Manufacturing, Efficiency

    9 Ways to Improve Manufacturing Efficiency

    Posted by Nik Seyferth on 2017 Dec 12

    Efficiency is good for any business. It doesn’t matter if your company is manufacturing or service oriented. Greater process efficiency always offers a wide range of benefits over "business as usual."

    On a broad level, manufacturing more efficiently can help cut costs, improve throughput and reduce environmental impact.  All of these general benefits lead to additional benefits down the road, from increased sales and quality to improved company image.

    Read on for 9 ideas to improve manufacturing efficiency.

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    Tags: Lean Manufacturing, Processes, Manufacturing, Efficiency

    3 Ways Lean Manufacturing Lowers Casting Costs

    Posted by Jim Smith, Jr. on 2017 Oct 17

    Looking to lower the cost of your casting purchases? The key is to find a foundry that incorporates lean manufacturing principles into the process. These three principles can be applied to manufacturing castings, driving down costs significantly:

    • Castability
    • Bottleneck Solutions
    • Optimizing Cycle Time
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    Tags: Lean Manufacturing, Metalcasting, Buyer's Guide, Purchasing Cast Products

    Lean Manufacturing and Castings

    Posted by Jim Smith, Jr. on 2017 Feb 10

    Looking to lower the cost of your casting purchases? The key is to find a foundry that incorporates lean manufacturing principles into the process. CASTABILITY, BOTTLENECK SOLUTIONS and OPTIMIZING CYCLE TIME are three principles when applied to manufacturing castings can drive cost out and lower your purchasing price.

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    Tags: Lean Manufacturing

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