"The efficient microscope of Lean Manufacturing has
allowed us to streamline our production processes
significantly. By focusing primarily on those things
necessary and useful, we are working to manufacture products
in a more concise, resourceful and creative manner.
These strategies have led to increased consistencies,
smoother operations and timesaving process."
Gary Walton, CEO/President
From the office to the shop floor, Process Improvement can benefit
any company in any industry by decreasing costs, shortening lead
times, reducing defects, and minimizing inventory, resulting in
increased capacity, improved customer satisfaction and higher
We can provide any level of process improvement
assistance, from a fully customized solution to training and guidance in any of
the tools and techniques. Whether your company is just getting started or is
well into their Process Improvement journey, we can help you achieve your next
level of excellence.
Process Improvement Tools and Techniques
View current courses offered by TMAC.
A series of activities designed to improve workplace organization and
standardization. Standardization in the workplace simplifies everyday
activities leading to time-saving improvements. The 5S activities are to:
- Sort through all items and remove unneeded items
- Set in order all remaining items, set limits, create temporary location
- Shine or clean everything and use cleaning as inspection
- Standardize the first 3 S's by implementing visual displays and controls
- Sustain the gains through self-discipline, training, communication, and total
Click here to download a 5S poster with more information.
A3 Problem Solving
A structured approach to resolving problems by getting to the root cause.
Using an A3 report, the user thoroughly defines and understands the issue,
addresses it with improvement, and manages the corrections.
The act of adding a mechanical device to a machine that allows it to operate
with reduced, non-continuous input from an operator. This allows the
operator to do other tasks while the machine is running, thus eliminating the
waste of underutilized employees.
The analysis of factors such as productivity, staffing, hours of operations,
equipment limitations, defects, setup time requirements, and equipment
maintenance requirements to determine the amount a given group, team, or
individual can produce.
The arrangement of machines and stations in close proximity to enable
flow for a single product or product group.
Positioning machines and work areas sequentially based on the steps
required to build a particular product in order to minimize wastes and implement
A systematic approach to identifying and eliminating waste
(non-value-added activities) through continuous improvement by flowing the
product at the pull of the customer in pursuit of perfection. It encompasses a
group of tools and philosophies that combine to build a system that provides
value to the customer, improves quality, reduces lead time, and enhances
A systematic approach to identifying and eliminating waste
(non-value-added activities) in administrative activities through continuous
improvement by flowing the product at the pull of the customer in pursuit of
perfection. It encompasses a group of tools and philosophies that combine to
build a system that provides value to the customer, improves quality, reduces
lead time, and enhances productivity.
The combination of Lean and Six Sigma into a single philosophy in
order to leverage the strengths of both. Lean is commonly thought of as a
way to improve process speed, while Six Sigma is primarily considered a quality
The use of simple devices, fixtures and procedures to eliminate errors
and ensure 100% defect free products.
The practice of storing inventory at the point where it will be used
instead of in a central warehouse.
A system in which items are only made or withdrawn when there is
demand from a downstream customer. A kanban is the signal that gives the instruction on what to do based
on the downstream customer’s activities. The kanban is very customizable
based on the need, for instance it can be a location on a floor, a cart, or a
When operators are given the means to perform inspection at the
source, before they pass it along. A final inspection station is not required
when quality at the source is used.
A tool used to review a setup in order to minimize the downtime.
It involves changing over a process to produce a different product in the most
An agreed upon set of work procedures that establish the best sequence
for each process within Takt Time while minimizing work in process. It enables a job to be
completed by the best current method to meet customer demand without waste.
Total Productive Maintenance
A method used to keep equipment producing only good product, as fast
as possible with no unplanned downtime by focusing on 8 Pillars:
- Planned Maintenance
- Autonomous Maintenance
- Early Equipment Management
- Focused Improvement
- Health & Safety
- Training & Education
- TPM in the Office
Toyota Production System (TPS)
A management philosophy combining Just-in-Time Manufacturing and Jidoka.
Just-In-Time refers to the manufacturing and conveyance of only “what is
needed, when it is needed, and in the amount needed.” Jidoka refers to the
ability to stop production lines, by man or machine, in the event of problems
such as equipment malfunction, quality issues, or late work.
Value Stream Mapping (VSM)
A technique used to analyze and design the flow of materials and
information required to bring a product or service to a consumer. Once the
product family is identified, the current method, to include information and
material flow, is documented. With this information, a future state map is
created, as well as an implementation plan. The benefits of completing a
Value Stream Map are to:
- Visually communicate processes
- Improve ability to scrutinize business processes
- Highlight areas of opportunity
- Provide insight into the decision making process
- Measure process efficiencies
- Create a vision
A technique where information is communicated by using visual signals
instead of texts or other written instructions. The design is deliberate in
allowing quick recognition of the information being communicated, in order to
increase efficiency and clarity.
Involves finding out how long a job or part of a job should take to
complete. The standard times are necessary to:
- Plan the work of a workforce
- Staff jobs, to decide how many workers it would need to complete certain jobs
- Schedule the tasks allocated to people
- Cost the work for estimating contract prices
View current courses offered.
TMAC South Central
Texas cities in the South Central TMAC Region
include: Austin, Georgetown, New Braunfels, Round Rock, San Angelo, San Antonio,
San Marcos, Seguin, Temple, Uvalde, Victoria, and Waco.
lean manufacturing • lean healthcare • six sigma •
green belt and black belt certification • 5S: workplace organization • A3
problem solving • automation • capacity analysis • cellular manufacturing •
facility layout • lean manufacturing • lean office • lean six sigma •
mistake-proofing • point-of-use storage • kanban • pull systems • quality at
the source • setup reduction • standard work • total productive maintenance
(TPM) • toyota production system (TPS) • value stream mapping • visual management • work measurement