high mix manufacturing

Manufacturing and Operations Strategy Consultants

Harmonic, Inc.

 DEHART CONSULTING, INC., working hand-in-hand with our factory personnel, redesigned our manufacturing areas and material flows to enable a 250% growth in output with only a 70% increase in floor space. Additionally, the changes were documented, implemented, and provided a clear path for future expansion. 


Mike Yost, Vice President, Operations Harmonic, Inc.

Vortex™ is a software embodiment of the patented technology developed for high-mix, non-repetitive manufacturers as an outgrowth of the DeHart Consulting LLC Lean Manufacturing methodologies.  Using the ground-breaking technology embedded in this Lean Shop Floor Control System as an add-on to an existing ERP system, expect 2 - 10x improvements in WIP and cycle time. In addition, because the Vortex™ demand-pull manufacturing system is completely algorithm-based, it also supports a machine learning system that will further improve your results over time.  With the advent on the Industrial Internet of Things (IIoT) and Industry 4.0, forward thinking companies are increasingly digitizing their production execution systems.  Vortex™ provides that opportunity to the high-mix manufacturer.

Our goal is to bring the same revolutionary improvements that the Kanban demand-pull system brought to the automotive, and other repetitive, manufacturing industry into the reach of producers with more complex workflows. Until now, demand-pull production, one of the key tenets of Lean Manufacturing, was inaccessible to non-repetitive discrete product manufacturers and semiconductor fabrication facilities because Kanbans just don't work well in this environment and the available shop floor control systems had no features available to support a pull system.  But the Vortex™ demand-pull manufacturing system changes all that by pulling work within the factory based on flow time instead of unit-replenishment.  Please take a look at the video below and then call or contact us for a discussion, demo, and/or an integration proposal.

Vortex™ Lean Shop Floor Control System - View Text of Video