Silfex provides high purity custom silicon components and assemblies for a broad base of high technology markets. As well as meeting a forecasted increase in demand for certain products, they wanted to improve the prototype manufacturing speed for new product development with their Rapid Part Manufacturing (RPM) Cell for their parent company, Lam Research Corp.
The company employed OPTIS TargetTwenty™ expertise to evaluate its inventory management and controls throughout all the value streams. An action plan was developed to drive down inventory and increase turns. Resulting inventory levels dropped 20% and turns increased from 8.9 to 11.8 turns per year.
OPTIS TargetTwenty™ helped Silfex improve on time delivery for prototypes to parent Lam from 51% to 100%. By developing a current and future state value stream map of their RPM Cell process, OPTIS went beyond recommendations to implement the solutions that delivered a tangible result.
Most importantly TargetTwenty™ led to increased production and manufacturing efficiency to meet new customer demands. Value stream mapping, capacity planning and quality improvement tools were used to eliminate bottlenecks, free up capacity and improve quality. Silfex increased production from 40 to 95 parts per week for one product family and 10 to 30 parts per week for another.
Additional projects included implementing standard work to improve productivity, product quality and new hire training. A Lean Facilitator class was conducted with extra days devoted to Kaizen principles. The training was designed to build the right skills set to sustain the improvements.