Cost Reduction
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Cost Reduction
At Implementation Engineers, we implement cost reduction initiatives for clients to achieve improvements in profitability and market competitiveness. Whether it's addressing labor inefficiencies, reducing excess inventory, or improving quality to minimize rework and lost product, we identify operational gaps and implement strategies to effectively address them. Our team is dedicated to working closely with clients to develop tailored solutions to unique challenges that will drive lasting performance enhancements.
41% throughput increase on Auto Grinder
$615K in cost reduction from alloy adds
IX® in Action
Our client is a high-quality gray iron castings foundry that utilizes green sandcasting process to produce ferrous castings for a wide range of industrial customers. Several known problems were causing the foundry to miss its on time delivery targets. Leadership recognized these improvement opportunities were immediately actionable, but they lacked the expertise required to implement sustainable solutions. IE implemented several projects in the product finishing department as well as the auto-grinding department aimed at increasing throughput and reducing cost.
- Conducted a Kaizen event on the Auto Grinder and identified improvements which yielded a 41% throughput increase
- Reduced bond addition per batch by 50% and also identified and corrected a measurement system issue through a DMAIC project
- Reduced alloy adds in the primary melt in a DMAIC project focused on the pearlite stabilizer
