A leading injection blow mold manufacturer in the Greater Toronto Area partnered with us to address high labor costs, recurring overtime, and delayed deliveries. By implementing Lean Six Sigma principles across key areas of their operations, the company achieved a 23% increase in profit margin per mold, along with significant reductions in waste, labor, and lead time.
Client Profile & Challenges:
This mid-sized manufacturer specializes in the production of high-precision molds for the plastics industry. Despite strong demand, they struggled with:
- Excessive labor costs and reliance on overtime
- Inefficient job scheduling and bottlenecks in the machining area
- Excessive rework due to inconsistent processes and quality issues
- Dependency on external subcontractors for mold base machining
- Frequent delays that impacted on-time delivery and customer satisfaction
These inefficiencies limited the company’s profitability and operational scalability.
Lean Six Sigma Implementation:
A hands-on Lean Six Sigma transformation was launched, with targeted solutions including:
- SMED (Single-Minute Exchange of Dies) to reduce machine setup time and downtime
- 5S Workplace Organization to improve tool access and eliminate non-value-added search time
- Kanban Scheduling to streamline WIP flow, reduce inventory, and improve shop floor visibility
- Workstation Relocation to eliminate unnecessary transportation and optimize flow
- Employee Training & Coaching to build internal capabilities and sustain improvements
Results:
The initiative delivered impressive results within a short period:
- Profit margin per mold increased by 23%
- Labor and overtime costs were significantly reduced
- Reduced reliance on subcontractors, bringing more work in-house
- Lead time shortened by 15%, boosting customer satisfaction and delivery reliability
- Enhanced team engagement and a stronger continuous improvement culture
Conclusion:
This project illustrates AM Saxum’s ability to deliver measurable operational and financial improvements in the mold making industry. With over 20 years of industry experience and a client-centric, results-driven approach, we help manufacturers reduce costs, improve lead times, and strengthen their competitive position.
