Lean Manufacturing

Our commitment to Lean Manufacturing insures that we never stop looking for ways to improve. We developed our smart cell manufacturing capabilities to deliver low cost and high quality solutions for our customers.

Our Lean Management system includes a bonus program that rewards all of our team members continuously improving our processes and effectively serving our customers. Each day we strive for perfection. When we do make a mistake, we use Six Sigma and root cause analysis to learn and prevent recurrence.

The Imperial Lean Manufacturing System is focused on four primary goals:

One: Improve quality:
In order to stay competitive in today’s marketplace, a company must understand its customers' wants and needs and design processes to meet their expectations and requirements.

Two: Eliminate waste:
Waste is any activity that consumes time, resources, or space but does not add any value to the product or service. There are seven types of waste:

  1. Overproduction (occurs when production should have stopped)
  2. Waiting (periods of inactivity)
  3. Transport (unnecessary movement of materials)
  4. Extra Processing (rework and reprocessing)
  5. Inventory (excess inventory not directly required for current orders)
  6. Motion (extra steps taken by employees due to inefficient layout)
  7. Defects (do not conform to specifications or expectations)

Three: Reduce time:
Reducing the time it takes to finish an activity from start to finish is one of the most effective ways to eliminate waste and lower costs.

Four: Reduce total costs:
To minimize cost, a company must produce only to customer demand. Overproduction increases a company’s inventory costs due to storage needs.

We have made great strides in the last 24 months to reduce waste while improving quality and delivery for our customers. We have dramatically reduced changeover times and created new capacity -  allowing us to quote very competitively - beating our off-shore competition. Our efforts have been rewarded by our customers with a number of new programs.