Lean Journey - Silfex
Company Profile: Silfex is a supplier of precision machined components to semiconductor, aerospace, automotive, and other industries. A recognized world leader in the silicon growing and fabrication-related business, Silfex is a division of Lam Research Corp. Silfex operates manufacturing plants in Eaton, Ohio, and Suzhou, China.
Project: As a primary supplier to top manufacturers of plasma etch equipment for the semiconductor industry, Silfex is in an industry forecasting a huge amount of growth. The company contracted with TechSolve Consulting for their factory and front office to create the capacity for this surge in business.
Working with Silfex employees on all levels, TechSolve helped develop a long-term solution for their needs. The team coached employees on how to identify and implement process improvements by conducting Lean assessments, mapping out processes and operations, and holding kaizen events. Visual management and operational metrics were also developed to manage inventory, production, and expectations.
Results: As a result of their extensive improvement efforts, Silfex was able to utilize TechSolve’s expertise to accomplish sustainable, company-wide results. The company has recently doubled both staff and plant size, while improving morale and flow. Silfex has also experienced a cost savings of $5.2 million and:
- 51% increase in core product line production capacity
- 72% improvement in lead time
- 60% decrease in work-in-progress and finished goods
- 15% reduction in materials costs
- Doubling of sales revenues
- Avoid the purchase of a new $1 million wire saw by reducing setup time on a guide roll
change on a wire saw by 42%
“In order to quickly create capacity, improve operations, and be able to sustain the results, it was critical that we find a partner that brought the technical skills and experience and who also was a good cultural fit. TechSolve fit the bill exactly.”
Mike Snell, General Manager
