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Lean Example Pool and Spa.png
Pool Products
 – Pool & Spa Components
Business Overview
Implementation Scope
Results

  • Integrated Manufacturer of pool & spa pumps, cleaners & filters

  • Annual Revenue $ 105M

  • 230 Employees

  • 300,000 s.f.

  • Engineering, Design, Manufacturing & Assembly

  • Pomona, California United States

  • Lean Production Introduced

    • ​Product dedicated work cells

    • One Piece Flow/pull

    • Set-Up Reduction Methodology

    • Value stream planning

  • Strategy Deployment Planning Focus

    • Complete integration from Engineering through manufacturing.

    • Pull Systems – Kanban 100% throughout manufacturing

  • Sales Growth:  50% increase

  • Productivity: ≈ 4.5% per year

  • WIP 4.6M – 440K  90% Decrease.

  • Avg Mold Changeovers per Day

    •  Before 9 @ 150 mins avg.

    •   After 61 @ 20 mins avg.

    •   > 30% @ under 7 mins

  • Product Work Cell Attainment to Demand – 94% avg. On Time Delivery: 

    • Before 18%  in 1999

    • Currently 98.2%

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