How does Lean Manufacturing in Die Casting Benefit You?

Lean Manufacturing Die Casting

What factors should you consider when choosing a quality aluminum die caster?  Choosing a manufacturer that follows True Lean manufacturing to minimize operating costs by reducing waste will prove to be the best choice for your company.  To be more efficient for your company while providing quality high pressure aluminum die casting, RCM Industries follows these principles. According to the Toyota Production System (TPS) eliminating waste is critical in creating Lean Manufacturing. 

As a customer of RCM Industries, you will benefit with a supplier practicing die casting lean manufacturing that provides your company:

  • Higher efficiency with more effective and productive hours to get your die cast part to you JIT (just in time)
  • Quality products and performance with less defects and rework
  • More timely production for better on time delivery performance

You will be interested to know that Lean Manufacturing is a business development practice that focuses on the actual needs of the customer by inhibiting waste from being introduced into the system.  Waste is classified in seven areas:

  • Overproduction
  • Inventory
  • Waiting
  • Motion
  • Transport
  • Defects
  • Over-processing

Waste and surplus drives up cost and does not add value to your product or service. RCM Industries keeps your costs lower by removing waste and surplus by implementing the True Lean process taught at the University of Kentucky of the Toyota Production System. 

Satisfied Customers = Lean Manufacturing + Continuous Improvement

As a valued customer, you will be pleased to know that executives and other departments such as operations, engineering, materials management and quality at all four of RCM Industries divisions have completed Lean Manufacturing training. To improve production in providing your aluminum die casting needs, RCM Industries is committed to Continuous Improvement in its Lean Manufacturing on-going training to ensure you the greatest in:

  • Quality
  • Waste removal and
  • Efficiency improvement in casting your parts

Specific areas of the plant were targeted for improvement in product flow. For example, after 5S, specific machining equipment was identified for relocation to create additional product rack space in an effort to improve product flow and inventory process.

Product Flow
Product Flow
Product Flow

Die Casting setup areas were targeted for improvement. New additions after 5s include visual reference guides for different sized components, improved storage racks and shelving for component storage, and new setup areas consisting of repurposed materials.

Setup Area
Setup Area
Setup Area

Standards have been implemented for die casting workspace cleaning.

Workspace Cleaning

New and improved walkways were created to improve plant safety while improving the layout of the plant. During these efforts, the decision was made to move the quality assurance inspection area away from the shipping coordinators doorway to make more room for product ready to ship. Team members contributed greatly to these efforts, and took great pride in the work being accomplished.

Walkway
Walkway
Walkway
Walkway

Improved lighting has been added to the new quality assurance inspection area. In addition, an inspection monitoring system has been implemented to replace the current paperwork processes.

Lighting
Lighting
Lighting

The production packaging storage area before and after 5s; identified space for customer product and packaging.

Packaging
Packaging

Stock is kept of the tools team members need to perform daily work, including paint, pens, markers, safety glasses, and other items. Team members scan their badge to get the tools they will need.

Tool Stock