Lean Tools Drive Lead Time Reduction
and training sustains the gains
With around 60 employees, this small but innovative company proudly serves as a U.S.-based design/build manufacturer of reliable small- and medium-sized motors.
Though Current Applications had consistently met client needs across multiple product lines, some team members who completed basic Lean training began questioning if certain processes could be made more efficient. They saw potential for saving time and improving product quality.
Through their Lean training with CITEC, Current Applications staff conducted a waste hunt and identified several operational areas for improvement. Together with CITEC, they selected two key product lines to target.
CITEC's Business Advisor helped the team create a Value Stream Map to assess the current state, determine cycle times, and measure overall lead time for producing and testing motors. Their existing practice of large-batch production caused lengthy lead times. CITEC introduced work balance charts to smooth the flow within the production cell, allowing the team to test smaller batch sizes. After making several improvements—such as cell design adjustments, standard work implementation, and 5S practices—they successfully transitioned to single-piece flow, resulting in reduced lead times and faster cycle times. Standardized work processes also enabled them to reallocate personnel across lines more efficiently, making them more agile and responsive to customer orders.
A similar Lean process was applied to a second product line with a new group of employees, yielding comparable results. More importantly, Current Applications now has multiple staff trained to continue Lean implementations in other work cells.
The results were clear: production increased 2.5 times, from 40 to 105 units per day, eliminating a 1,000-unit backlog. Lead time was cut by 50%, and work-in-progress inventory dropped from 105 to just 5 units, significantly improving internal costs. An internally certified Lean White Belt now oversees ongoing training and sustains these gains.
Operations Manager Scott Barker says, "We continue to rely on CITEC to help us stay competitive in the electric motor market. By providing our employees with the training and time to improve their work areas, we are empowering our workforce for the future."
