LEAN Manufacturing
                                        Creating the LEAN Enterprise

  
              Reduced Lead Times                                  Improved Return on Invested Capital
              Reduced Throughput Times                      Improved EBITDA
              WIP Inventory Reduction                             Reduced Manufacturing Overhead and Quality Costs

Summary

LEAN Manufacturing is the Charles Brooks Associates, Inc. proven approach to higher rates of throughput,
improved product quality with reduced quality cost, and improved customer delivery and satisfaction levels.  
The Charles Brooks Associates, Inc. approach to LEAN Manufacturing is a participatory activity involving all
employees and staff - a structured approach enabling your company to harness its human resources to
change the culture of manufacturing.  CBA LEAN takes advantage of the synergies of your organization to
gain the benefits of reduced material inventory cost, reduced throughput times, and reduced manufacturing
overhead costs to produce greater margins and ROIC.

The objective is to make LEAN improvements in your operation with the involvement and understanding of
all concerned.  Participatory trials are carried out to confirm the projected improvements.  In this way,
employees are able to participate in the process of establishing new LEAN procedures, methods,
performance standards and goals.

LEAN Manufacturing Features

LEAN means SPEED!!!

                             •        Measurement of CYCLE EFFICIENCY
                             •        Analysis and Definition of Constraints
                             •        Quantifying Cost of Constraints
                             •        Choosing the “Target”
                             •        Forming the Problem Solving Team
                             •        Developing Team Problem Solving ability
                             •        Generating Improvement Ideas
                             •        Conducting Improvement Experiments
                             •        Developing Comprehensive Action Plan
                             •        Implementation with the Total Workforce
                             •        Measurement of CYCLE EFFICIENCY to determine received benefit
Our Approach

Our work with clients during the development and implementation of the CBA LEAN Manufacturing process
is a combination of Training, Industrial Engineering, Structured Problem Solving, Good Manufacturing
Practice, and Employee Involvement.  Supported by the solid manufacturing experience which your
management and our specialists have acquired during their manufacturing careers. Our staff has been
carefully trained to assist your company to introduce changes and to obtain improvements with the
involvement and understanding of your personnel at all levels.

The first step is a discussion with one of our senior specialists, followed by a short survey to determine the
scope for our work, the benefits that may be expected and the cost involved. When invited to work with you,
we act as a catalyst or team leader in introducing the LEAN Manufacturing approach, ensuring the
participation of all concerned and guiding the successful implementation of improvements.  Appropriate
members of your staff are trained to continue the LEAN Manufacturing approach successfully after we leave.

Achievable Benefits

                           1.        Operating Margin Improvement – 155%

                          2.        ROIC (Return on Invested Capital) Improvement – 230%

                          3.        EBITDA Increase –  300%

                          4.        Manufacturing Lead Time Reduction – 700%

                          5.        WIP Inventory Turns Improvement – 250%
                                       
Services
Charles Brooks Associates, Inc
Performance Technology