Our hands on experience provides us with a unique and comprehensive understanding of the difficult problems that manufacturing organizations are faced with on a daily basis and how process improvement systems work in implementation, not just in theory.

Our skills range from engineering, technical and manufacturing to human resource systems, organization development and training. Our accomplishments include: 

• Successful engineers and manufacturing professionals
• Authors of over a dozen published books and training systems
• Malcolm Baldrige National Quality Award Board of Examiners
• Certified Myers-Briggs Administrator
• Licensed Professional Engineers
• ASQC Certified Quality Engineers
• Frequent Speakers at National and International Conferences

Resource Engineering works with manufacturing businesses to provide turn-day system solutions to business strategy and manufacturing problems.

Project objectives typically include the identification and analysis of options to address:

• Effective facility layout including cellular operations.

• Throughput improvement.

• Cycle time reduction.

• Equipment set-up and changeover time reduction.

• Reduction in inventory.

• Visual factory concepts.

• Mistake-proofing of processes.

• Application of statistical process control and statistical improvement techniques.

Implementation of Work Cells for Saw Blade Manufacturer
Analyzed workflow and developed process layouts and a scope and cost estimate for converting functional departments into product-family based work cells. Managed the implementation of the cells and brought the project in under budget and ahead of schedule. Cells resulted in 12% labor savings.

Site Consolidation; Conversion from Functional to Cellular Operations
Designed process layout for consolidating two manufacturing operations into one site for a plastic closure manufacturer. Space for the consolidation was freed by converting the operation from functional departments to market-focused manufacturing cells. Scope of activity also included the development of the project scope and cost estimate, the preparation and presentation of project summary to secure a bank loan to fund the project, the preparation of bid packages, and management of the project. Project was brought in on-time and within budget.

Paper Converting Operation—Coating Line Project Management
Managed project to remove two coating lines and replace them with a high-speed coater. Project included the coordination of the equipment supplier, general contractors, and customer support groups. Through value-added analysis, the project was brought in under budget for items within the original scope.

Lean Manufacturing Implementation at Repair Facility for Large Aircraft Engine Components
Trained five teams in lean manufacturing concepts including the 5S’s, set-up reduction, and work simplification concepts. Facilitated team activities that resulted in a 70% reduction in the time to develop the repair scope and cost; 50% reduction in machining center set-up time; and an improvement in facility organization and housekeeping. Developed cellular layout to handle a 200% growth in sales with a 40% expansion in space.

Warehouse Layout and Packaging Improvement for Urethane Sheet Manufacturing Facility
Analyzed packaging and warehousing operations to identify process and workflow improvements. Based on the analysis, developed recommendations for improvements in the packaging operations and developed a warehouse layout, warehousing equipment recommendations, and a scope and cost estimate for the new warehousing operations.

Site Relocation; Conversion to Cellular Operations for Instrumentation Manufacturer
Designed layout of assembly, test, and packaging operations to convert these operations into product-focused work cells. Activities included work simplification, line balancing, and the preparation of a scope and cost estimate.

Cellular Operations for Label & Nameplate Manufacturer
Reorganized traditional functional layout into work cells with streamlined process flow. Lead to reduced process cycle times, lower direct labors, less inventory, and better quality. Project included workflow analysis, new layout, project scope, cost, justification, and logistical plan, modification of work practices, and cell leader training.

Urethane Molding Operation Expansion
Process workflow analysis and plant layout to incorporate new process lines and to improve both effectiveness and efficiency of overall operation. Project included expansion of building and utilities, relocation of existing processes to improve workflow, and modification of supporting quality systems to reflect simplified practices.

Office Products Manufacturing Multi-Plant Consolidation
Developed master plan for consolidation of two manufacturing sites. Included detailed plant layout (with improved workflow), scope and cost estimate for corporate approval, construction grade drawings, time-based project plan and bid package.

Turbomachinery Parts Manufacturer and Services Supplier
Integrated multi-site order processing system and formalized project management approach to initiate project accountability; reach on-time shipment objectives; enhance customer satisfaction; and improve profitability.

Paper Converting Manufacturing and Distribution Center
Designed layout and managed installation of automated packaging lines for high volume roll and sheet product while plant operated at record levels of production. Provided turn-key construction management. Developed process operating procedures and conducted training for manufacturing personnel.

Blood Collection Needle Manufacturing Facility
Completed scope and cost estimate, design, and construction management of fast track program for start-up company. Manufacturing came on-line within six months of starting the scope and cost estimate. Construction on-time and under budget.

Aircraft Engine Remanufacturing Facility
Created master plan for reorganizing 250,000 ft² facility into product line manufacturing cells. Trained steering committee in cellular manufacturing concepts and methodology to train the rest of the workforce. Designed and assisted in implementation of first cell. Designed second and third cells. Trained cell leaders in cellular operations and business concepts.

Resource Engineering has been helping manufacturing companies improve process flow and manufacturing inefficiencies for more than ten years. We always welcome and encourage prospective customers to talk to people in companies we have worked with to get a feel for our approach and capabilities. They will tell you that we live up to our promise to deliver results that will improve the bottom line of your business. If we can't, we don't take the job.

Call 1-800-810-8326 to find out more information about the Consulting for Manufacturing Services we offer.

We stand behind all of our work and guarantee you will get results.