high mix manufacturing

Facility Design Consulting and Industrial Engineering

They Trust Us

Services

Industrial Engineering
Facility design based on world-class, lean operations models to achieve productivity, sustainability, and future capacity requirements.
Supply Chain Development
Aligning the company's supply-side partnerships with its demand-side customer relationships to achieve seamless harmony through the supply chain.
Software Development
Interfacing with ERP using tools such as AngularJS, .NET, PHP, and MeteorJS to simplify user-facing production and supply-chain systems.

DeHart Consulting

DeHart Consulting is unique among manufacturing management consulting firms in that we use a team-based approach in the vast majority of our assignments. When the client's personnel are brought into the work early and when key client stakeholders are involved with our lean manufacturing consultants the results are measurably successful. While this approach requires an investment of time from the client, it increases overall commitment and a buy-in that pave the way for the successful implementation of the work. This is especially the case in lean manufacturing consulting assignments where the result of the work requires considerable change management.
Successful Engagements

Lockheed Martin SB Focal Plane

Manufacturing Facility Design | Goleta, CA

lockheed martin practise areas

lockheed martin 180

Project
Manufacturing Fabrication & Assembly

Location
Goleta, California

Project Type
Industrial

Project Size
240,000 sf

Project Duration
Design – 6-months
Build – 9-months

LM-SBFP is a world-wide leader in the design and fabrication of defense and aerospace components and was tasked with doubling its production throughput within its existing manufacturing footprint. DCI was hired to redesign the factory layout within the context of lean manufacturing principles and to assure the overall capacity increase.

The high-mix production environment involved a broad range of processes and products. DCI analyzed the value chain and reworked the facility layout delivering a 3x reduction in production span and the needed 2x increase in capacity.

A novel technology for demand-pull production was proposed to minimize floorspace dedicated to work-in-process inventory. Design Engineering, Facilities, and Operations Management staff we part of the team that assured the designs met the needs of all involved.

The design won the approval of corporate management and was implemented over a 2-year period.

Services

  • Lean Manufacturing
  • Facility Design
  • Construction Oversight

Vendor Coordination

  • Production Equipment
  • Information Technologies
  • ESD Facilitation

XILINX, Inc. AsiaPac Headquarters

Manufacturing Facility Design | San Jose, CA | Singapore

xilinx practise areas

 

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lockheed martin 180

Project
Manufacturing, Engineering, & Distribution Center

Location
Changi Business Park, Singapore

Project Type
Industrial

Project Size
290,655 sf

Project Duration
18 months

Xilinx Inc is the leader in programmable logic devices with 50% of the world market share. In the brief to DCI, space efficiency and sustainability was a core design consideration.

The warehouse is designed with automation in mind with direct material handling conduits to the production floor. Smart features such as air flushing, light management system and intelligent environmental features provide a productive working environment.

Tasked to ensure the incorporation of worldwide demand projections to Xilinx’s headquarters, DCI proposed features that enabled a mere 1.1% increase in construction investment but reaps an expected $500,000 savings each year.  DCI was responsible for analyzing production rates and capacity to assure that the resulting design was capable of meeting the needs of the 5-year forecast.

The project was awarded Platinum Green Award by Building & Construction Authority of Singapore, the first ever for a privately developed industrial facility.

Services

  • Facility Design
  • Construction Oversight

Vendor Coordination

  • Production Equipment
  • Warehouse Automation
  • ESD Facilitation
  • Security

CalAmp

Operational Supply Chain Design | Oxnard, CA

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lockheed martin 180

Project
Supply Chain & Manufacturing

Location
Oxnard, CA

Project Type
Industrial Profit Improvement

Project Size
150,000 sf

Project Duration
Design – 6-months
Conversion – 18-months

CalAmp is a technology company that specializes in telematics hardware and software and was struggling with high costs and an inefficient factory. DCI was engaged to assist in restructuring the Supply Chain, Physical, and Organizational design of the company to improve its performance and profitability.

The factory was redesigned into customer-focused modular teams along with all associated capital equipment. The Supply Chain was re-organized into major commodity bundles, contracts renegotiated in a Liability-limiting, highly flexible procurement framework, and overall material costs were reduced by 35%. Demand-pull logistical technologies were implemented in the factory execution systems, reducing WIP and FG levels by 60%. New Product Introduction teams were developed reduce time-to market and customer satisfaction.

The company’s operations were successfully turned around and profitability rapidly improved. The company's stock moved from less than $2 per share to over $45 per share within 2 years of its transformation.

Services

  • Lean Manufacturing
  • Facility Design
  • Supply Chain Strategy

Vendor Coordination

  • Production Capital Equipment
  • Information Technologies
  • Direct Material Suppliers

Pure Fishing

Manufacturing Facility Design | Spirit Lake, IA

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lockheed martin 180

Project
Operations, Manufacturing Fabrication & Assembly

Location
Spirit Lake, IA

Project Type
Industrial

Project Size
300,000 sf

Project Duration
Design – 6-months
Conversion – 9-months

Pure Fishing is an 80-year old company with storied brands such as Berkeley baits and Abu-Garcia reels and was struggling to keep up with the demands of world-class customers such as Walmart. The company was generating obsolete inventory and not meeting its customers’ On-Time Delivery expectations

DCI was engaged to assist in the physical and organizational transformation of the company into highly focused, high-volume, factories based on Lean Manufacturing Methods.

The factory was divided into individual business units with operational KPIs and customer-focused organization structures, and then physically redesigned to meet its externally-focused demands for line, bait, rods, and reels.

The company’s operations were successfully turned around and profitability rapidly improved. It later attracted a $1.3B investment from a Private Equity firm.

Services

  • Lean Manufacturing
  • Facility Design
  • Construction Oversight

Mike Stephens

Mike G. Stephens

Professional Experience

Director, Engineering Services - Satellite Electronics Manufacturer
Vice President, Operations - Lighting Systems Manufacturer
Manufacturing Engineering Manager - RF Components Manufacturer
Engineering Manager – Hand-held Computer Manufacturer

Profit-minded, performance oriented manufacturing and operations professional offering 25+ years progressive experience in Plant Operations, R&D, Applications Engineering, Field Service, Manufacturing Engineering and Off Shore Procurement. A hands-on strategic planner, decision maker and problem solver with a proven track record of leadership and excellence in manufacturing by utilizing Lean Manufacturing and TQM techniques. Profit and Loss responsibility in addition to providing technical liaison support to external customers and suppliers.

  • Development and setup of electronic manufacturing processes, both domestic and offshore.
  • Leader of ISO 9000 certification teams.
  • Mechanical Design of laser diode transceivers for SAN market.
  • Set up of micro-electronic assembly line to manufacture integrated laser circuits: scribe/saw process through final test and burn-in.
  • Evaluation of battery manufacturing processes for computer applications
  • Produced complex cable TV power hybrids and communication devices for the military.
  • Responsible for all hermetic semiconductor devices produced in the Far East.
  • Set up of seven offshore semiconductor and PCB assembly facilities in the Far East and Mexico. Complete responsibility for plan layout, staffing, training, equipment selection and process control.
  • Created microelectronics facility for Xerox. Chief Engineer for microelectronics packaging at all Xerox division. Full manufacturing responsibility for R&D transfer to production.
  • Developed proprietary process to produce charge coupled devices for copy machines.
  • Formalized basic design rules for microelectronics packaging at each of the six companies.
  • Increased manufacturing yields to 95% from levels as low as 50% through material selection, process design and analysis of compatibility and tolerance at the design level.
  • Evaluated economics of automation and use of robotics. Where appropriate, designed and installed complete systems, reducing product labor content by 50%.

Education

Mechanical Engineering Program, Cerritos College, 1973
Business Major at Cal State University Fullerton, CA 1973 –1974
Served on S.E.M.I. Standards Committee on Hermetic Devices

Personal

Mr. Stephens was born in Southern California. He is married to Jackie and has four children.