A biotechnology manufacturer produces consumable cartridges at a single workstation under a microscope. Facing the challenge of increasing production from 95 units per week to 135 per week, they required solutions to scale their operations efficiently. When they came to Adonis Partners, their scaling concept involved adding a work-station and hiring additional employees to staff it. However, it would take each new employee approximately 2-3 months to build capability in the manufacturing process.

To address these challenges, Adonis first established a baseline using a Value Streaming Map (VSM) to analyze the current flow. Next was an overhaul of the current system to create a standardized process and balanced workflow. The Adonis consultant trained the employees in the Lean White Belt toolkit so they were able to contribute to improving the new process. Three specific areas were addressed during this phase: sequencing, measuring, and retraining. Daily huddles were also introduced to the client team to help sustain these changes.

By focusing on standardizing workflows, balancing processes, and engaging employees in root cause analysis, the client exceeded their growth targets. The Lean initiatives implemented by Adonis Partners increased productivity by 8% and reduced processing time by an astounding 25%. Training in Lean principles empowered employees to sustain these changes through daily huddles and continuous improvement practices, resulting in a more efficient and scalable operation.