Ithaca, NY www.transonic.com
Company Profile: Transonic Systems, Inc. makes fluid flow measurement devices. Its biomedical products measure and confirm liquid flow during surgery, post-surgery, hemodialysis and research application.
The company was founded in 1983 by Cornelis Drost, who invented the transit-time ultrasound flowmeter, and now employs 130 people in Ithaca.
Transonic sells its ultrasound transit-flowmeters, hemodialysis, laser Doppler perfusion and angioplasty monitors to surgeons, nephrologists, interventional radiologists, research scientists, and original equipment manufacturers throughout the world.
Situation: Transonic System's management attended a LEAN manufacturing seminar and realized the potential benefits of implementing it.
Solution: AM&T developed a customized Lean Enterprise training, partially funded by a New York State Department of Labor grant.
AM&T trained a key group of employees on the basics of Lean, and helped plan and manage implementation, including:
- Principles of Lean Manufacturing with Live Simulation (Lean 101)
- Lean for the Office
- Value Stream Mapping
- 5S System and Workplace Organization
- Cellular Flow Manufacturing
- Pull/Kanban Systems
- Mistake Proofing
- Kanban/Pull training reduced product cycle time 40 percent, to three days from five. It also reduced inventory, with a goal of saving 54 percent of inventory costs.
- Reduced cycle times via Cellular training by 75 percent in one cell; reduced inventory 50 percent; and added four workstations by reclaiming misused space.
- Mistake Proofing training increased first-pass yields for one particular product to 95 percent from 78 percent.
- Stock room improvements reduced shelving needs 20 percent and kitting times 30 percent.
- Increased sales.
- Reduced lead time.
- Improved customer satisfaction.
- Improved workforce morale.