Case Studies WinMan Enables Lean Manufacturing for Lantech

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	WinMan Enables Lean Manufacturing for Lantech

WinMan Enables Lean Manufacturing for Lantech

Technology Category	Analytics & Modeling - Predictive Analytics Functional Applications - Enterprise Resource Planning Systems (ERP) Functional Applications - Manufacturing Execution Systems (MES)
Applicable Functions	Process Manufacturing Quality Assurance Warehouse & Inventory Management
Use Cases	Inventory Management Manufacturing System Automation Predictive Maintenance Supply Chain Visibility
Services	Software Design & Engineering Services System Integration Training
Challenge	Lantech, Inc. of Louisville, Kentucky, faced a significant challenge in their journey to Lean Manufacturing. The existing information systems at the time of Lantech’s conversion to Lean Manufacturing were inadequate to support the new processes under consideration. These systems would have prevented Lantech from achieving its objectives for improvements in product design, manufacture, product quality, and delivery. The company needed an information system that was compatible and synergistic with their redesigned processes and Lean Thinking. This required a comprehensive search for a suitable software solution that could support their Lean business process re-engineering. Read More
About Customer	Lantech, Inc. is a company based in Louisville, Kentucky, recognized for its extensive work in Lean Manufacturing. The company is featured in the book 'Lean Thinking' by Womack and Jones, which highlights their journey to Lean Manufacturing. Lantech operates in an environment where virtually all products have lead-times to customers that are less than the lead-time from suppliers for non-Kanban items. This necessitates a proactive approach to inventory management and procurement. Lantech's commitment to Lean Manufacturing has led them to seek out advanced information systems that can support their innovative processes and improve overall efficiency and product quality. Read More
Solution	After completing their Lean business process re-engineering, Lantech selected the WinMan advanced information system to support their new processes. WinMan offers a range of features that enable Lean Manufacturing, including powerful product configuration tools, automated Kanban routines, flexible backflush processing, and inventory control by location. The system supports both internal and external Kanban processes, allowing for seamless integration with suppliers and efficient material procurement. WinMan also provides robust planning and forecasting capabilities, enabling Lantech to manage material resource availability and supplier relationships effectively. The system's support for cell manufacturing and point-of-use material flow further enhances operational efficiency. Additionally, WinMan's internet capabilities keep customers and suppliers informed, facilitating better communication and collaboration. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Predictive Analytics

Functional Applications - Enterprise Resource Planning Systems (ERP)

Functional Applications - Manufacturing Execution Systems (MES)

Applicable Functions

Process Manufacturing

Quality Assurance

Warehouse & Inventory Management

Use Cases

Inventory Management

Manufacturing System Automation

Predictive Maintenance

Supply Chain Visibility

Services

Software Design & Engineering Services

System Integration

Training

Challenge

Lantech, Inc. of Louisville, Kentucky, faced a significant challenge in their journey to Lean Manufacturing. The existing information systems at the time of Lantech’s conversion to Lean Manufacturing were inadequate to support the new processes under consideration. These systems would have prevented Lantech from achieving its objectives for improvements in product design, manufacture, product quality, and delivery. The company needed an information system that was compatible and synergistic with their redesigned processes and Lean Thinking. This required a comprehensive search for a suitable software solution that could support their Lean business process re-engineering.

About Customer

Lantech, Inc. is a company based in Louisville, Kentucky, recognized for its extensive work in Lean Manufacturing. The company is featured in the book 'Lean Thinking' by Womack and Jones, which highlights their journey to Lean Manufacturing. Lantech operates in an environment where virtually all products have lead-times to customers that are less than the lead-time from suppliers for non-Kanban items. This necessitates a proactive approach to inventory management and procurement. Lantech's commitment to Lean Manufacturing has led them to seek out advanced information systems that can support their innovative processes and improve overall efficiency and product quality.

Solution

After completing their Lean business process re-engineering, Lantech selected the WinMan advanced information system to support their new processes. WinMan offers a range of features that enable Lean Manufacturing, including powerful product configuration tools, automated Kanban routines, flexible backflush processing, and inventory control by location. The system supports both internal and external Kanban processes, allowing for seamless integration with suppliers and efficient material procurement. WinMan also provides robust planning and forecasting capabilities, enabling Lantech to manage material resource availability and supplier relationships effectively. The system's support for cell manufacturing and point-of-use material flow further enhances operational efficiency. Additionally, WinMan's internet capabilities keep customers and suppliers informed, facilitating better communication and collaboration.

Impact #1	Lantech achieved significant improvements in operational efficiency and product quality by implementing WinMan. The system enabled a single piece flow Lean Manufacturing system, which led to a 250% increase in sales and a 40% reduction in factory space used. Inventory turns increased from 2.3X to over 20X, representing an 87% reduction in inventory with an improved service level. The number of items under external Kanban control increased to over 10,000, delivered to the point of use in the manufacturing cell. The number of purchase orders written manually decreased from over 5,000 per month to less than 1,700 per month, with orders created, consolidated, and transmitted electronically. The use of the Self Billing Invoicing routine with agreed vendors resulted in early payment discounts of more than $20,000 per month. Sales order fulfillment time was reduced by 67%, and there was a significant improvement in product quality and customer satisfaction. Monthly accounts were distributed by email by noon of the first working day of the month, and overall profitability increased enormously.

Impact #1

Lantech achieved significant improvements in operational efficiency and product quality by implementing WinMan. The system enabled a single piece flow Lean Manufacturing system, which led to a 250% increase in sales and a 40% reduction in factory space used. Inventory turns increased from 2.3X to over 20X, representing an 87% reduction in inventory with an improved service level. The number of items under external Kanban control increased to over 10,000, delivered to the point of use in the manufacturing cell. The number of purchase orders written manually decreased from over 5,000 per month to less than 1,700 per month, with orders created, consolidated, and transmitted electronically. The use of the Self Billing Invoicing routine with agreed vendors resulted in early payment discounts of more than $20,000 per month. Sales order fulfillment time was reduced by 67%, and there was a significant improvement in product quality and customer satisfaction. Monthly accounts were distributed by email by noon of the first working day of the month, and overall profitability increased enormously.

Benefit #1	Sales increased by 250%
Benefit #2	Factory space used reduced by 40%
Benefit #3	Inventory turns increased from 2.3X to over 20X, representing an 87% reduction in inventory

Benefit #1

Sales increased by 250%

Benefit #2

Factory space used reduced by 40%

Benefit #3

Inventory turns increased from 2.3X to over 20X, representing an 87% reduction in inventory

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Overview

WinMan Enables Lean Manufacturing for Lantech

Operational Impact

Quantitative Benefit