Lean & Six Sigma Process Optimization
Transform Your Operations. Reduce Waste. Improve Efficiency.
At Amer Welding Solutions, we help aerospace and defense manufacturers achieve operational excellence through Lean Manufacturing and Six Sigma methodologies.
Our approach combines data-driven analysis, proven process improvement tools, and AI-enhanced insights to optimize your workflows, reduce costs, and improve quality — all while keeping your team engaged and empowered.
Our Approach: Structured, Data-Driven, Results-Oriented
Step 1: Process Discovery & Mapping
We start by visualizing your current workflows to understand how materials, information, and people move across your shop floor.
We use tools like:
- Value Stream Mapping (VSM) → Visualizes the entire end-to-end process.
- Spaghetti Diagrams → Shows operator and material movement to identify inefficiencies.
- Process Flow Charts → Maps dependencies, handoffs, and decision points.
Output Example:
A clear before-and-after process map showing cycle times, rework loops, and bottlenecks, allowing you to see your waste points at a glance.
Step 2: Performance Measurement
We use data-driven analysis to measure your current performance:
- Cycle Time Analysis → Time taken at each step.
- Throughput Efficiency → Output vs. capacity.
- OEE (Overall Equipment Effectiveness) → Availability, performance, quality metrics.
- Sigma Level Calculation → Defects per million opportunities.
Output Example:
An interactive dashboard showing KPIs like downtime, yield, and scrap rates — updated in real time.
Step 3: Problem Identification & Root Cause Analysis
We analyze why inefficiencies occur and address their causes, not just their symptoms.
Key tools include:
- Pareto Analysis (80/20 Rule) → Pinpoints the top contributors to inefficiencies.
- 5 Whys Methodology → Identifies the root cause behind recurring issues.
- Fishbone Diagrams (Ishikawa) → Visualizes contributing factors (e.g., machine, method, material, manpower).
- Failure Mode & Effects Analysis (FMEA) → Quantifies risk and prioritizes solutions.
Output Example:
A Root Cause Heat Map highlighting the top 3 issues causing 70% of production delays.
Step 4: Process Optimization & Solution Design
Once bottlenecks are identified, we design optimized processes using Lean & Six Sigma methodologies:
- Kaizen Events → Rapid improvement workshops to achieve quick wins.
- SMED (Single-Minute Exchange of Die) → Reduces setup/changeover times.
- 5S Workplace Organization → Streamlines workstations for efficiency.
- Kanban Systems → Implements visual pull systems to improve flow.
- Poka-Yoke → Mistake-proofing techniques to eliminate defects.
- AI-Assisted Forecasting → Uses predictive analytics to optimize workflow and planning.
Output Example:
A redesigned production layout showing reduced travel distances, faster part flow, and improved resource utilization.
Step 5: Control & Sustain the Gains
To ensure improvements are sustained long term, we implement:
- Standard Operating Procedures (SOPs) with visual guides.
- KPI Dashboards that track performance.
- Training Programs for operators, engineers, and managers.
- Continuous Improvement Roadmaps to foster a culture of operational excellence.
Output Example:
A Lean Dashboard showing live progress toward productivity, quality, and delivery targets.
Technical Tools & Solutions We Use
| Category | Tool | Purpose |
|---|---|---|
| Process Visualization | Value Stream Mapping (VSM) | Map end-to-end process flows |
| Workflow Optimization | Kanban, 5S, SMED | Improve flow, reduce waste |
| Quality Improvement | DMAIC, Poka-Yoke, SPC | Reduce defects, ensure stability |
| Data Analysis | Sigma Calculations, OEE, KPIs | Quantify performance and losses |
| AI Integration (optional) | Predictive Scheduling, Digital Twins | Automate forecasting, simulate changes |
Industries & Applications
- Aerospace Welding & Machining
- Defense Component Manufacturing
- Fabrication & Assembly Shops
- Job Shops Managing Complex Fabrication Projects
Expected Results
Our Lean & Six Sigma consulting delivers tangible, measurable outcomes:
- 20–40% reduction in cycle times.
- 15–25% improvement in throughput.
- Up to 30% scrap reduction using statistical controls.
- Higher on-time delivery rates and customer satisfaction.
- Improved employee engagement through better workflows.
Why Partner With Amer Welding Solutions
- M.S in Lean Manufacturing & Six Sigma.
- 12+ years optimizing aerospace and defense manufacturing processes.
- Hands-on expertise with NADCAP, AQS, AS9100, and advanced manufacturing standards.
- Practical, results-driven approach — we implement solutions, not just reports.
Amer Welding Solutions 