Manex Services, Consultant Overview and Project Highlights

It long has been recognized that the manufacturing sector is the foundation for economic vitality in the United States.

Since 1995, The Corporation for Manufacturing Excellence (Manex) has provided a broad array of proven solutions and resources exclusively to manufacturers, distributors and their supply chains, enabling them to compete on a global scale. We use a holistic and proven approach—from strategy through implementation—to impact all facets of business performance. The results: growth, profitability, and competitive advantage.

Contents

• About Us

• Philosophy

• Approach

• Services and Solutions

• Team

• Case Studies

• Contact Us

This document and its contents in their entirety are Copyright ©Manex. All Rights Reserved.

“There has been an amazing transformation in the operations workforce with regards to Lean implementation. A complete

paradigm shift has occurred enabling each employee to feel and know they are empowered to use the Lean tools. The 5S

principles of Lean have been implemented by the employees at an astonishing rate, showing how this concept is now a belief.”

- Jes Vargas, Director of OperationsZ-World

About Us

Boost Performance

In today’s extremely competitive global environment, manufacturers and distributors face significant challenges to improve business performance. Now, more than ever, innovative business practices are essential to create a vigorous and sustainable future in manufacturing.

“A lack of innovation is the most serious challenge facing the U.S. manufacturing base, because global competition will continue to force increases in productivity, movement of commodity manufacturing overseas, and displacement of American labor.” — Thomas W. Eagar and Christopher Musso, Massachusetts Institute of Technology

Forward-thinking U.S. manufacturers are rising to the challenge and prospering with the support of dedicated partners like Manex. Manex helps companies turn business challenges into business opportunities. We provide high-value consulting and business advisory services that help manufacturers significantly increase growth, productivity, quality, and profitability.

We work with you holistically, with a proven approach and unique skills that deliver immediate results and position you for long-term success, while enabling you to serve your current customers effectively without undue distraction.

Every day, we help manufacturing companies of all sizes use innovative practices to implement real business change and achieve competitive results.

About Us

Knowledge and Expertise

Our manufacturing expertise covers the extended value chain — from supply chains through manufacturing and distribution — for a broad range of industry sectors including aerospace, automotive, bio-tech, communications, consumer packaged goods, food, heavy manufacturing, high-tech, medical devices, pharmaceuticals, and precision manufacturing.

Our diverse team brings an average of 20 years experience to deliver a powerful depth and breadth of industry and business know-how — from strategy through operations. We are nationally recognized for our strategic, enterprise-level expertise and extensive front-line manufacturing experience.

As a member of the National Institute of Standards and Technology (NIST) Manufacturing Extension Partnership (MEP) program, we draw upon a national network of resources covering broad expertise in manufacturing best practices. We work in partnership with MEP to solve your challenges by advancing best practices in manufacturing operations, methods, and processes.

With this unique blend of expertise, we help you become stronger and ultimately more profitable.

About Us

Analytical Approach > Dramatic Impact

Our team uses a fresh, analytical approach to help drive complexity out of your business and facilitate your success.

We quickly examine your existing business and operations to identify potential problem areas and leverage points to transform your business. Working collaboratively with you, we establish priorities and implement solutions that deliver the optimum financial and operational impact.

These objectives become the scorecard for our team. We systematically remove bottlenecks and roadblocks—while developing new ways to create value — by continuously working with you throughout the process to deliver the greatest return on investment.

Manex prides itself on your long-term results and business success. The business value we provide is measured by an independent third-party (NIST) to ensure we meet and exceed your business objectives.

“What was accomplished here in one week, with support from Manex was extremely valuable and worthwhile. In all my years of manufacturing, I do not recall output as tangible as what we have

just experienced. We are seeing visible, very positive changes in our staff and in the quality of our products.”

- Rick Brown, VP of OperationsWestcor

Philosophy

Manufacturing Vitality

Manex operates under the principle that manufacturing and distribution are the cornerstones of the U.S. economy, playing a central role in American prosperity as one of the most vital sectors for economic growth.

Our sole purpose is to help manufacturers and distributors navigate successfully through volatile market conditions to gain a competitive edge. We help you deploy world-class manufacturing techniques to improve productivity levels, shorten supply chains, and deliver more customer value.

With our roots in manufacturing, our active participation in MEP, and a longstanding dedication to knowledge transfer and implementation, we have a continued commitment to develop and deliver services that help you thrive in a competitive environment.

Your success is our measure of success.

Change Innovation

The key to success in today’s rapidly evolving environment is to use change as a competitive edge. With an eye on creating value, Manex helps you become more agile, harnessing change to transform your enterprise.

Our team works closely with you, as a business partner, identifying and implementing ways to enhance your strengths and stay ahead of the competition. We help you build tomorrow’s enterprise today; beyond adapting to change; creating it.

With clarity of vision and exceptional discipline, we help you create a sustainable competitive advantage.

Philosophy

“Company president, George Whitehill stated that this is the best cash flow position that AMS has ever been in. Where we are right now sets the stage for us to become the Silicon Valley solution for new product introduction as the cornerstone for us to go through

dramatic growth in the next couple of years.”

- Ed Bless, VP of Business ExcellenceAMS

Approach

Integrated Effectiveness

We work with our clients using a holistic approach looking at the business as an integrated, cohesive whole. By engaging all levels of the organization – from senior management to line operators – we quickly achieve dramatic results that are sustained for the long-term. Our disciplined approach supports the alignment of strategy, process, people, and technology to help you effectively achieve your objectives and exceed your performance goals.

Our full range of integrated services is tailored to your unique business needs. Using proven methodologies and tools, in-depth expertise, and innovative solutions, we help you implement business improvements for a flexible, highly responsive enterprise.

Together our holistic approach and differentiated services translate into increased business value for our clients.

Rapid ROI > Sustained Results

Our focus is to enable fast returns on your investment and sustained results. With our holistic approach, we pinpoint high-impact process improvements and identify critical ways to streamline operations to quickly achieve cost efficiencies and increased profits. Coupled with long-term strategic vision, we facilitate ongoing alignment of manufacturing operations with your overall business objectives. We deliver tangible results and

the agility to adapt to changing needs and market realities. Our projects average more than 600% annualized ROI - that's a $6 return for every dollar invested in these activities after just 12 months.

Throughout the process, we share information, insights, and best practices helping your existing workforce adopt process improvements throughout your value chain. Knowledge transfer ensures new practices are sustained for long-term, measurable results.

Our comprehensive services connect business objectives to operational execution. We arm you with the tools and knowledge to respond to customer demands more quickly, improve profitability, and drive down costs throughout your organization.

Through a collaborative, results-driven approach, we help you transform your business to maximize your return on investment.

Approach

“Working with Manex made the process seem very easy in terms of efficiency and smoothness. Many companies could learn valuable

lessons from Manex. We look forward to working with Manex in the future when the need arises.”

- David Allen, VP Manufacturing and Operations

Marinco

Comprehensive Services

Tailored Manufacturing Solutions

Manex offers a full range of high-value consulting and business advisory services for the manufacturing sector that spans the entire supply chain.

By offering integrated services, we provide solutions that enable you to:

• Createandmaintaincompetitiveadvantage• Positionforsustainedgrowthandprofitability• Increaserevenue• Improveefficienciesandreducecosts• Reducecostsacrossthesupplychain• Optimizeprocesses• Reducecycletime• Manageforcontinuousimprovement

To help you achieve quantifiable results we offer an integrated portfolio of offerings in the

following areas:

• Strategy• People• Process• Performance

Strategy

As your strategic business advisor, Manex helps you identify and create new sources of value and growth in your enterprise. With a fresh, analytical look at your market environment, required core competencies, and current state of operation, we help you identify opportunities and develop viable strategies to realize them.

Our experienced team works with you to clarify business objectives, prioritize and execute upon corporate initiatives, and define and implement performance measures and processes that help you gain sustained results.

Our services and solutions include:

• CorporateStrategy&BusinessPlanning• MarketStrategy• M&AAdvisory;Post-M&AIntegration• Organizational&OperationalDesign• ProductLineExtensions/Rationalization• Manufacturing,Distribution&ChannelStrategy• In/Outsourcing(Make/Buy)• CustomerSatisfaction,Loyalty&Retention


People

With relatively high labor costs, U.S. manufacturers and distributors must seek out ways to compete on productivity, product superiority, quality, and responsiveness to customer needs. These competitive pressures put a high premium on the skills, morale, and commitment of employees.

With people as one of your greatest assets, Manex helps you enhance the skills and knowledge of your workforce with innovative training and development programs. We specialize in providing comprehensive solutions to ensure your workforce is skilled in advanced manufacturing methods and technologies to enable future innovation in your enterprise. Through collaboration with universities and NIST, we deliver the latest knowledge and thought-leadership in innovative manufacturing techniques to keep employees’ knowledge and skills at the leading edge.

We help your employees – at all levels – develop the advanced skills required to meet the demands of an increasingly complex environment.


• KnowledgeManagement• ManagementLeadershipTraining• LeanOperations&SixSigmaTraining• ISO9001-2000Implementation&CertificationAssistance• CaliforniaETPTrainingFunds


Process

The road to maximizing business performance frequently demands improving your enterprise’s core processes. Our process consulting services align strategies, people, and technology with best-practice business processes to deliver considerable business improvements and measurable outcomes.

Our proven set of best practices, supported by experienced professionals within manufacturing and distribution, allow us to deploy customized high-value solutions to eliminate business process roadblocks and waste, while simultaneously enabling growth. We identify opportunities for improvement through a diagnostic review of current business processes, systems, and internal controls and determine whether they add value and contribute to profitability.

Manex enhances your business performance by making complex customer requirements more manageable through optimized and streamlined business processes. We specialize in helping manufacturers and distributors increase revenues and reduce costs by refining and eliminating inefficient pro-cesses and by introducing and implementing advanced processes.

Our process consulting approach couples quantifiable savings with significant business improvements. Beyond the manufacturing floor and throughout the organization, our team can show you innovative ways to deliver business optimization across the value chain.


• LeanOperations• SixSigmaQualityManagement• ActivityBasedManagement• ProcessDesign• SupplyChainManagement• Procurement• QualityManagementSystems• RCA,TQM,HACCPandcGMP


Performance

Manufacturing performance management is increasingly important as pressures to innovate continue to rise. To be on the manufacturing forefront, companies must raise the bar on performance, quality, and cost with continuous improvement efforts.

Manex helps develop and implement the right performance metrics to measure organization effectiveness and its impact on profitability and productivity. We work with you to improve management decision making with timely, relevant information important to achieving your business objectives. We implement processes that automatically and proactively alert management to potential impacts, allowing you to make timely decisions to optimize operations rather than simply react to events. Our experts help you implement best practices, tools, metrics, and scorecards for competitive performance (with supporting what-if analysis) to model impacts and create a closed loop process for continuous improvement.

We infuse performance management techniques in all of our services, knowing it is critical to the success of your strategy, process, and people development initiatives.


• ExecutiveDecisionSupportSystems• Internal/ExternalBenchmarking• ManagementDashboards&Scorecards• ActivityBasedCost/ProfitManagement• KeyPerformanceIndicators(KPIs)• ProfitOptimization• EventManagement


“The Manex team was instrumental in assisting our team during our Value Stream Mapping Roadmap development sessions.

As a result, we have been working diligently on the implementation of our Roadmap which has had significant impact

on reducing our lead time, increasing our quality and increasing our value added activity during our processes.”

- Mauro Folena, Director of Operations

Coherent, Inc.

Team

In-depth Knowledge > Hands-on Experience

Manex offers a proven and experienced management team with extensive industry expertise and aconsulting team with significant experience in business strategy and manufacturing operations. We bring applied knowledge and practical solutions, assisting diverse organizations optimize processes to drive down supply chain costs, maximize the value of existing assets, and convert intellectual capital into profit.

With an average of 20 years of business strategy expertise and manufacturing experience, each of our consultants has the industry skills and tools to quickly understand your needs, tailor solutions to meet your business challenges, and deliver solid results. Our management team engages directly with you, utilizing a wealth of experience in strategy, planning, and operations, to develop innovative solutions that deliver important business benefits.

From business strategy and processes to hands-on implementation, we share experience and best practices to help transform your business.

Our professional team is committed to your success.

Team

Name

GeneRussell

Title

CEO/Executive

Director

Education

•BA-Economics

University of California,

LosAngeles

Years of Experience

Over 30

Strategy

People

Process

Performance

Area of Expertise

•CorporateStrategy

•BusinessDevelopment

•SalesandMarketing

•OperationsManagement

•ProcessImprovement

•ProductLineDevelopment

Name

Nana Cho

Title

DirectorofCorporate

Development&

Executive Consultant

Education

•MBA-CornellUniversity

•BA-Universityof

Southern California,

Annenberg School for

Communication

Years of Experience

Over15

Strategy

People

Process

Performance

Area of Expertise

•CorporateStrategy

•CompetitiveAnalysis

•Benchmarking

•ComplexProject

Management

Name

Bill Browne

Title

DirectorofClientServices

Education

•MBA-Universityof

Detroit

•BSinEngineeringArts-

Michigan State University

Years of Experience

Over 34

Strategy

People

Process

Performance

Area of Expertise

•BusinessStrategy

•LeanManufacturing

•CertifiiedSixSigma

Master Black Belt

(CSSMBB)

•QualitySystems

Name

GaryWaters

Title


Education

•BA-WesternMichigan

•MaterialsManagement

(APICS)&Purchasing

(NAPM) Certifications

Years of Experience

Over 33

Strategy

People

Process

Performance

Area of Expertise


•Purchasing

•MaterialsManagement

•Just-in-Time(JIT)

Environments

Name

MichaelLevin

Title


Education

•BAinMarketing-

California State University,

Chico

Years of Experience

Over 30

Strategy

People

Process

Performance

Area of Expertise

•SalesTraining

•StrategicPlanning

•MarketingPlans

•LeadershipTraining

•PresentationSkills

Training

Team

Name

Eric W. Wiedenmann

Title


Education

•MBA-KelloggSchoolof

Management,

Northwestern University,

•BSinMarketing-

Ashland University

Years of Experience

Over 23

Strategy

People

Process

Performance

Area of Expertise

•StrategicMarketingPlans

•BusinessDevelopment

&SalesProcesses

•CompetitiveIntelligence

•Benchmarking

Name

Philip Cullen

Title

Senior Consultant

Education

•MBAinFinance&

International Business -

Santa Clara University

•BAinPhysics-Sonoma

State University

Years of Experience

Over 22

Strategy

People

Process

Performance

Area of Expertise

•StatisticalProcessControl


•ContinuousImprovement

•EngineeringChangeMgmt

•ProcessQualification

Name

RichardJeffreyLewis

Title

Management Consultant

Education Years of Experience

Over31

Strategy

People

Process

Performance

Area of Expertise

•QualityManagement

•Maintenance&Safety

•PlantOperationsMgmt

•ISO9001:2000&OSHAs

•ProjectManagement

Name

GregCho

Title

Senior Consultant

Education

•BSinElectrical

Engineering - University

ofCalifornia,Davis

Years of Experience

Over9

Strategy

People

Process

Performance

Area of Expertise

•SupplyChainManagement


•ProductionManagement

•SixSigma

•ISO9001Certification

Bios

Gene RussellCEO/Executive Director

Overview/BackgroundGeneRussellisCEO/ExecutiveDirectorofManexandhasover30yearsofseniorexecutivestrategicplanning,operationalmanagement, and consulting experience in the manufacturing and technology sector. With his extensive knowledge of manufacturing operations, he has developed and implemented key strategic initiatives for companies, allowing them to improve performanceandachieveprofitablegrowth.Hehasastrongbackgroundinsalesandbusinessdevelopmentandakeenunderstanding of manufacturing strategies in the global environment.

PriortojoiningManex,Mr.Russellledcompanieswithinseveralrapidlychangingindustriesincludingtelecommunications,wirelessmobile,consumerelectronics,majorappliancesandmostrecentlythefireplaceandhomedécorsegments.AsCEOofPilgrimHomeandHearthforthepastsixyears,herestructuredoperationsintheU.S.andChina,diversifiedandrevampedproductlines,expanded distribution channels domestically and internationally, and developed a management team to produce record results.

Mr.Russell'spreviousexperienceconsistsofkeyleadershiproleswithavarietyofmanufacturingandtechnologyfirms,includingOregonScientific,HaierAmerica,SOSWirelessCommunications,SDITechnologiesandAT&T.Intheseexecutivepositions,hewasinstrumentalindevelopingnewbusinessplans,coreoperationalimprovementsanddiversifiedproductplans,aswellaslaunchingsignificantbusinessdevelopmentandsalesinitiatives.Instart-upfirms,helednewventureswithconceptualideas,anddevelopedthemintosuccessfuloperatingentitieswithindustryleadershippositions.Hehasalsoservedasaboardadvisoranddistributionconsultant.

Mr.RussellholdsaB.A.inEconomicsfromtheUniversityofCalifornia,LosAngeles.

Areas of Expertise

•CorporateStrategy•BusinessDevelopment•SalesandMarketing•BusinessTransformation&Globalization•EarlyStageManagement•DistributionManagement•ProductLineDevelopment•OperationsManagement•ProcessImprovement

strategy people process performance

Bios

Nana ChoDirector of Corporate Development & Executive Consultant

Overview/Background

Ms.Chohasover15yearsofextensiveconsultingandindustryexperience,spanningseveralindustries,includingconsumerproducts, high tech, financial services, entertainment, and telecommunications. She has in-depth expertise leading and implementing initiatives in the areas of corporate strategy, new product development, strategic alliances, and market analysis to help companies improve performance and achieve profitable growth.

Ms.Cho’sindustryexperienceincludesholdingseveralseniorroleswithCitigroupinNewYorkandLondonwheresheanalyzedmulti-regional acquisition options in the financial services market and formulated growth strategies to improve market leadership positions across multiple business lines. In addition, Ms. Cho was a consultant with Mercer in their Communication practice.

Ms.ChoholdsanMBAfromCornellUniversity’sJohnsonGraduateSchoolofManagementandaBAwithhonorsfromtheUniversityof Southern California’s Annenberg School for Communication.

Areas of Expertise

• CorporateStrategyandM&A• CompetitiveAnalysisandBenchmarking• MarketResearch• FinancialAnalysis• NewProductDevelopment• ComplexProjectManagement

Representative Clients

AT&TWireless,AmericanExpressCompany,TheJ.PaulGettyTrust,Avnet,Inc.,WebEx,AveryDennisonCorporation,WellPointInc.,AllstateInsuranceCompany,TheWaltDisneyCompany,Nestle,Citigroup,Inc.,andAramarkCorporation.


Bill BrowneDirector of Client Services

Overview/Background

Mr. Browne has over 34 years of extensive manufacturing experience and expertise in general management, manufacturing operations, qualitysystems,engineering,productdevelopmentandcontinuousimprovementinitiatives,includingLeanManufacturingandSixSigma. As an experienced change agent, he has led numerous process improvement initiatives resulting in top-line and bottom-line growthacrossarangeofindustrysectorsandgeographies,includingChina,HongKongandtheUK.

PriortojoiningManex,Mr.BrownewasGeneralManageratTriangleCoatings,Inc.wherehewasresponsibleformanagingtwomanufacturingoperations.Duringhistenure,heledtheorganizationtoachievea20%improvementinproductivity.Previously,Mr.Browne held executive management positions with a number of organizations including Morgan Crucible, Consolidated Container CompanyandMattel,Inc.,wherehewasinstrumentalindrivingculturaltransformationsthatenhancedprofitability,productivityandefficiency.UnderhisleadershipatMattelToysHongKong,theoperationsdoubledproductionwithoutaddingresourcesthroughtheimplementationofJust-In-Timemanufacturingtechniques.DuringhisworkwithGeneralMotors,hedevelopedtheprocessfortheVacuum Insertion of Engine Pistons, resulting in a pre-patent research disclosure.

Mr.BrownehaslednumerousLeanManufacturing,quality(ISO9001,8D),productoptimization,consumerpricingandworkforcedevelopmentprogramsthatachieveddramaticimprovementsinproductivityandcompetitiveness.HehasledimplementationsintheareasofProductDesignandOptimizationusingDFMEAsandPFMEAsandwaspartoftheimplementationteamforaJ.D.EdwardsERPsystemintoan$80MMcompany.Mr.BrownehasalsoachievedtheSixSigmaMasterBlackBelt(SSMBB)andCertifiedDesignforSixSigma(CDFSS).Mr.BrowneholdsanMBAwithhighhonorsfromtheUniversityofDetroit,andaBSinEngineeringArts(acombinationofEngineeringandGeneralBusiness)fromMichiganStateUniversity.

Areas of Expertise

• Plant/OperationsManagement• SupplyChainManagement&Logistics• LeanManufacturing&SixSigma• QualitySystems• ProjectManagement


GeneralMotors,MattelInc.,TRW,Inc.,TriangleCoatings,MorganCrucibleCompany,LLC,ConsolidatedContainer,KelseyHayesCompany,BretfordManufacturing,DiagnosticsfortheRealWorld,WilkinsonManufacturing,Cellotape,Cytosport,NorthropGrummanandCrossfieldProducts

Bios


Bios

Gary WatersExecutive Consultant

Overview/Background

Mr. Waters is a top-performing, solutions-driven consultant with more than 33 years of experience directing manufacturing operations. An effective communicator capable of building professional relationships based on trust and mutual benefit, Mr. Waters’ years in the manufacturing arena include positions as Plant Manager, Materials Manager, Purchasing Manager, and Technical Support Manager.

Whileworkingforseveraltier-onesupplierstoToyotaandNUMMI,theGeneralMotors/Toyotajointventure),Mr.Watersdevelopedhis expertise in lean manufacturing and continuous improvement utilizing the Toyota Production System.

Mr. Waters holds a Bachelor of Business Administration degree in Business Management from Western Michigan and has earned certificationsinbothMaterialsManagement(APICS)andPurchasing(NAPM).HehasalsobeenfeaturedinarticlesinPurchasingMagazineandRyderResourceMagazine.

Areas of Expertise

• LeanManufacturing• Purchasing• MaterialsManagement• Just-in-time(JIT)Environments• Health,Safety,SexualHarassment,&WorkplaceViolenceEducation• StressManagement


FirestoneTire&Rubber,JohnsonControls,TrimMasters,Toyota,GeneralMotors,KSAutomotive,Inc.,ProtectiveTreatments,Inc.,and Masco Corporation.


Bios

Michael LevinExecutive Consultant

Overview/Background

Withover30yearsasanEntrepreneurandSmallBusinessConsultant,Mr.Levinandhiscompany,CustomSolutionsInc.,offerSales,PresentationSkillsandBusinessDevelopmentConsulting.Mr.Levin'spersonallydevelopedmethods,throughyearsofentrepreneurialandcorporateexperience,haveprovidedhighlysuccessfulresultsforFortune50companiesthroughstartupentrepreneurialventures.

Mr.Levinhasdeliveredhisuniquemessageonradioandtelevisionshowsaroundthecountry.Heistheauthorof"HowtoMakeYourBusinessMoreSuccessful"and"HowtoTakeYourProducttoMarket".Hehasspokenbeforenumerousgroupsandcorporationsandhasbeenpublishedinbusinessandtradejournals.HehasalsobeenfeaturedinEntrepreneurMagazine.

Asasuccessfulentrepreneur,Mr.Levinhaspersonallylaunchedbothproductandservicebusinessesfromscratchanddevelopedthemintomulti-milliondollarventures.Hisproducts,includingthosehehaspatented,havebeensoldworldwideinover30,000retailoutlets.Herecentlysoldhisautomotivemarketingbusinessthatservicedover130dealershipsinNorthernCalifornia.

Mr.LevinwasanexecutivewithPepsiCola,runningverysuccessfuldivisionsinSanFrancisco,OaklandandReno,Nevada.Healsoconsultedfor Pepsi, developing and delivering sales management training programs.

Mr.LevinreceivedaBAinMarketingfromCaliforniaStateUniversity,Chico.

Areas of Expertise

• SalesTraining• StrategicPlanning• MarketingPlans• LeadershipTraining• PresentationSkillsTraining• CommunicationSkillsDevelopment


PepsiCola,Clorox,Oracle,PacificWorldCorporation,DreamTimeInc.,TheFullPlate,ClocksEtc.,CommunicationCatalysts,GoldenBy-Products,Goodwin-Cole,Let'sPlayRecreation,ModularRubberDrains,MillenniumMolding,MBTechnologyandnumerousentrepreneurs with new product launches.


Bios

Eric W. WiedenmannExecutive Consultant

Overview/Background

Mr. Wiedenmann has over 23 years of in-depth expertise in sales, marketing and business development, helping organizations increase profitability and improve competitiveness. As a management consultant, interim executive, and sales executive, he has advisedover100clients,includingFortune500companies,mid-sizedfirmsandstartups,increatingnewsourcesofrevenueandgeneratingprofitablegrowth.HisindustryexperienceincludesexecutivemarketingandbusinessdevelopmentpositionsatMasco,AveryDennison,BPandCBCIndustries.

Mr. Wiedenmann received an MBA from Kellogg School of Management, Northwestern University and a BS in Economics and MarketingfromAshlandUniversity.HeisanexecutivelectureratAshlandUniversityandhasgivenbusinessdevelopmentspeechestonumerousCEOandCOOadvisorygroups.Mr.Wiedenmannisalsothepublisherof“TheRevenueAccelerator”newsletterandauthorof“HowtoincreaseSalesinaDownMarket”.

Areas of Expertise

• StrategicMarketingPlans• BusinessDevelopmentandSales• CompetitiveIntelligence• NewMarketPenetration• CustomerSatisfactionBenchmarking• NewProductLaunches


IBM,Fujitsu,TRWAutomotive,Tru-SiTechnologies,Inc.,Turbolinux,BradleyCorporation,MascoCorporation,AveryDennisonCorporation,BP,CBCIndustries,andSGI.


Bios

Philip CullenSenior Consultant

Overview/Background

Mr. Cullen has over 22 years experience as a project engineer and operations analyst, contributing to the successful execution of product development projects in high technology manufacturing environments and national laboratories. As an experienced operations specialist, he has developed, documented and automated manufacturing and test processes to reduce waste, reclaim materials and enhanceprofitability.Hehasresolvedcriticalprocessandsupplychainissues,savingmoneyandtime,anddirectlycontributingtotheintellectual property assets of organizations. Mr. Cullen has extensive experience with Agile product life cycle management software and is a skilled strategist, capable of resolving problems at the procedural level to enable progress.

Prior to joining Manex, Mr. Cullen served in a variety of senior engineering positions in high technology environments, including Photon Dynamics,Inc,SOIDirect,Nutool,Inc.,AccucorpTechnicalServicesandRead-RiteCorporation.HispreviousexperiencealsoincludesmanagementofatechnicalgroupinAdvancedManufacturingEngineeringatLamResearch,aswellasresearchpositionswiththeLawrenceBerkeleyLaboratoryandtheUCBerkeleySpaceSciencesLaboratory.

Mr. Cullen received an MBA in Finance and International Business from Santa Clara University and a BA in Physics, with a concentration in Chemistry from Sonoma State University.

Areas of Expertise

• DeviceManufacturing• 5-PhaseProjectManagement• StatisticalProcessControl• LeanManufacturing• ContinuousImprovement

Process Optimization•


PhotonDynamics,Inc.,SalvadorImaging,LamResearch,AccuCorpTechnicalServices,Read-RiteCorporation,LawrenceBerkeleyLaboratory,UCBerkeleySpaceSciencesLaboratory,LosAlamosNationalLaboratory,NASA,EuropeanSpaceAgency,Brelje&RaceLaboratories,Heller,Ehrman,White&McAuliffe,CoursonInvestments,ACWIB,CellotapeandNorthropGrumman

International Operations•Engineering Change Management•ProcessQualification•Yield Improvement•CostReduction•Process Planning•


Bios

Richard Jeffery LewisManagement Consultant

Overview/Background

Mr.Lewisbringsover31yearsofextensivemanufacturingexperienceassistingorganizationsinimprovingproductivityandtransforming their operations. As an award-winning professional in leading quality management practices, he has in-depth expertise in totalqualitymanagement,maintenancemanagement,safetyharmonization,andISOcompliance.Mr.LewishasledstrategicmanufacturinginitiativesinorganizationsacrossNorthAmerica,Europe,andtheCaribbean.Hisexperiencespansanumberofsectors including the manufacturing, food, semi-conductor, and energy industries.

Mr.LewisistherecipientofthedistinguishedQualityAssuranceInstitute“BestoftheBest”awardforthebestqualityprocesssoftware.Inaddition,heisahighlyaccreditedexpert,asaqualitymanagementfacilitator,principalauditor,andaccreditedISO9000consultant.

Mr.Lewisisafrequentspeakeratindustry-leadingconferencesandhasauthoredanumberofarticlesinvariousindustrypublications,includingMaintenanceTechnologyandFoodQuality.HealsohasaU.S.PatentforTechnicalSafetyConfirmationwhichincludes techniques for safety lockouts using a mobile device.

Areas of Expertise

• QualityManagementSystems• Maintenance&SafetyManagement• Plant/OperationsManagement• ISO9001:2000,OSHAS18000,ISO22000&ISO14000• ProjectManagement,Training&Facilitation


LJEngineering,Inc.,STGMachine,HaywardQuartzTechnology,Inc.,WestCoastQuartz,SequoiaBrass&Copper,APPROSystems,Inc.,Screen-Tech,Inc.,SAE,Inc.,NASAM,Inc.,PacificRubber,andSemitec.


Bios

Greg ChoSenior Consultant

Overview/Background

Mr.ChoisahighlyskilledSeniorConsultantwithover9yearsofexperienceinmanufacturing,productionandsupplychainmanagement.Mr.Cho'sexpertiseincludessupplychainintegration,statisticalanalysis,LeanManufacturing,SixSigmaandQualityManagement Systems.

PriortojoiningManex,Mr.ChowasaQualityEngineerwithSanmina-SCIwhereheanalyzedandimprovedSupplyChainQualityissues and developed new supplier processes to meet customer requirements. While in Manufacturing Management with Keola PrecisionTechnology,Mr.Chomanagedprojectsandproduction,implementedLeanManufacturingmethodsandledprojectsthroughproductionlifecycles.Mr.ChoalsohasexperienceintheimplementationofERPsystems,assistinginthedeploymentofEpicorVista8.0andadministeringcompany-wideshopfloordatacollectiontraining.HehasactivelyusedOracle11iandAgilefordataentry,dataextraction and report generation.

Mr.ChohasaBSinElectricalEngineeringfromtheUniversityofCalifornia,Davis.HeisaCertifiedQualityEngineer(CQE)andhasachievedtheSixSigmaGreenBeltdesignation.

Areas of Expertise

• SupplyChainManagement• LeanManufacturing• ProductionManagement• SixSigma• ISO9001Certification


AppliedMaterials,ASML,BrooksAutomation,Inc.,CellotapeIncorporated,CiscoSystems,Flextronics,HolzRubberCompany,KirkhillRubberCo.,LAMResearch,Martin-BakerAmerica,MilitaryAircraftParts,NovellusSystems,Inc.,Sanmina-SCI,SuperTrapInc.,YaskawaElectricAmericaandLaTortillaFactory


“Manex has been a tremendous partner helping us with our Lean transformation. With their in-depth expertise, on-site support, and

commitment to results, they have been instrumental helping us not only achieve significant results to date, but also ensuring that we

have the processes in place to sustain them in the future.”

- Tommy Dockery, Western Region Manager

Del Monte Foods

Client Summary

Client Name

Del Monte Foods

Industry

Food ProductsStrategy

People

Process

Performance

Solutions

•LeanTransformation

Client Name

United Services

Industry

Transportation EquipmentStrategy

People

Process

Performance

Solutions

•LeanCertification


Client Name

Coherent, Inc.

Industry

ElectronicsStrategy

People

Process

Performance

Solutions


Client Name

PowerLight Corporation

Industry

EnergyStrategy

People

Process

Performance

Solutions


Client Name

Northrup Grumann Electronic Systems

Industry

ElectronicsStrategy

People

Process

Performance

Solutions

•Leadership&ManagementTrainingProgram

Client Summary

Client Name

T.G.I.F. Body Shop

Industry

AutomotiveStrategy

People

Process

Performance

Solutions

•ComprehensiveLeanTrainingProgram

Client Name

Wilkinson Manufacturing

Industry

Metals/MachinesStrategy

People

Process

Performance

Solutions

•OptimizedNewFacilityFlow&WorkCellLayout


Client Name

Max Machinery, Inc.

Industry

Metals/Machines

Strategy

People

Process

Performance

Solutions

•ISO9001:2008Certificationqualitymanual


•6-SigmaDMAICprocess

•Practicalproblemsolving&RootCauseCorrectiveAction

(RCCA)

Client Name

Goodwin-Cole Co.

Industry

Textiles - Tents and Awnings

Strategy

People

Process

Performance

Solutions

•Hi-impactmarketingcollateral

•Salesprocess


•Leadandcycletimes

Client Name

Cellotape, Inc.

Industry

Printing/Labels

Strategy

People

Process

Performance

Solutions

•5-yearsalesgrowthplan

•Currentstateandfuturestatemapsandlayouts

•5SandLeanManufacturing

Client Summary

Client Name

Pacific Biosciences

Industry

BiotechStrategy

People

Process

Performance

Solutions


Client Name

La Tortilla Factory

Industry

FoodStrategy

People

Process

Performance

Solutions

•FacilitiesLayoutwithimprovedsetup/changeoverprocess

•AdditionalCapacity

•Overtimeandlaborsavings

Client Name

Millennium Molding

Industry

Plastics/Rubber/Composites

Strategy

People

Process

Performance

Solutions

•MarketingStrategy

•HighPerformanceWebsite(SEO)

•Rebranding

•Revampedmarketingmethods/materials

Client Name

Biotech Firm

Industry

BiotechStrategy

People

Process

Performance

Solutions

•OperationalAssessment&5S

•Automation

Client Name

Large Rubber Recycler

Industry

Recycling

Strategy

People

Process

Performance

Solutions

•FacilitiesLayout&FlowProcesses

•StrategicVisioning

•BusinessCaseTemplateforCustomerOrderingProcess


Client Summary

Client Name

Cultured Marble Products

Industry

Construction/Contractors/

Remodeling

Strategy

People

Process

Performance

Solutions

•LayoutandFlowAnalysis

•Comprehensive5Straining

•LeanManufacturing,KPIsandPPE

•QualityandCriticalControlPoints

•EnergyAssessment

Client Name

Galaxy Desserts

Industry


People

Process

Performance

Solutions

•ValueStreamMapping

•InitialImplementationand"Tuning"

•WorkforceDevelopmentSupport

Client Name

Crossfield Products Corporation

Industry


Remodeling

Strategy

People

Process

Performance

Solutions


•ComprehensiveTrainingProgram

•5S

Client Name

Gayler Construction

Industry


Remodeling

Strategy

People

Process

Performance

Solutions

•Strategy

•ManagementFacilitation

•MarketingAnalysis

Client Name

InsulTech LLC

Industry

Insulating CompoundsStrategy

People

Process

Performance

Solutions


•High-levelPPSPrograms

•Re-layoutofOfficeandFloor

•KanbanReplenishmentSystem

Client Summary

Client Name

Z-World

Industry

ElectronicsStrategy

People

Process

Performance

Solutions


Client Name

Vicor - Westcor Division

Industry

ElectronicsStrategy

People

Process

Performance

Solutions


Client Name

C&H Specialists

Industry


People

Process

Performance

Solutions


Client Name

Advanced Material Solutions (AMS)

Industry

ElectronicsStrategy

People

Process

Performance

Solutions

•ComprehensiveSupplyChainManagementProgram

Client Name

Sequoia Brass & Copper

Industry

MetalsStrategy

People

Process

Performance

Solutions

•ISO9001:2000Certification

•ISO9001:2000QualityManagementSystem

Client Summary

Client Name

Applied Thin Film (ATP)

Industry

SemiconductorStrategy

People

Process

Performance

Solutions

•ISO9001:2000Certification


•WorkforceDevelopment

Client Name

Morgan Hill Precision, Inc.

Industry


People

Process

Performance

Solutions


Client Name

Cholestech Corporation

Industry

HealthCareStrategy

People

Process

Performance

Solutions

•ComprehensiveTrainingProgram

•BusinessCommunicationSkills

•ExperimentDesign

Client Name

Laird Manufacturing

Industry


People

Process

Performance

Solutions


•DeepDiveQualityAssessment&ValueStreamMap

•KaizenEvents

client >

Del Monte Foods

company profile >

Produces, distributes, and markets premium, quality branded and private label food and pet products. Market leading brands in fruit, vegetable and tomato products

A fruitful transformation improves OEE by 4.7% and reduces scrap by more than 30%.

Clients

client business need >

ToacceleratetheadoptionofLeanacrossthe company, the Modesto California ContinuousLinewasselectedasamodelto showcase the substantial benefits of transforming the line with the implementationofLeanpractices.Thislinewas chosen for its complexity in operations - high volume of fruit, 24x7 operations, and seasonality. Achieving significant productivity improvements in this intricate environment would further the rapidadoptionofLeanpracticesthroughout the company.

results delivered >

Increased efficiency of its entire ContinuousLinewithsustainable,enterprise-wide improvements supported by employees who are empowered, engaged, and energized by a culture of Lean.Specificresultsinclude:• Improved Overall Equipment Effectiveness(OEE)by4.7%•Reducedscrapbyover30%•Leancultureofcontinuousimprovement (plant-wide training of 233 employees, owners and champions established, Kaizenevents,LeanManagement Center)

approach >

In collaboration with management, Manex developedacomprehensiveLeanprogram. A complete life cycle approach was used - awareness, immersion, implementation, and sustainability. An in-depth assessment was performed to understand the environment and determine the key areas of focus and supporting metrics.TheteamwasimmersedintoLeanwith comprehensive training, tools, and processes-5SVisualFactory,TPM,standardized work, practical problem solving, and cultural change activities.

Clients

client >

United Services

company profile >

Leader in full-service commercial aviation global Maintenance, Repair & Overhall (MRO)

Powerful Lean Certification Program standardizes Lean practices and strengthens the organization.


UnitedAirlineshasmadeLeanacorporate-wide priority with the objectives ofcreatingaLeanculturecommittedtoincreasing quality and productivity throughout the organization. Since November2005,astrategicteamhasbeen leading the charge for continuous improvement across United Services. As part of this priority, United Services turned to Manex to help ensure the consistent implementationofLeanthroughthedevelopmentofaLeancertificationprogram.

results delivered >

Significantresultsinclude:

•185employees,representingall departments, have completed the program•8sessions:eachwith32hoursofLean curriculum, customized simulations and Kaizen Events•BronzeLevelLeanCertification Knowledge Certificates•InnovativePartnerships:Grantsand university credits provided in partnership with San Mateo County Community CollegeDistrict

approach >

Working with the United Services leadership team, Manex developed a powerful, customized certification program to help participantslearnLeanprinciplesandtoolsto achieve measurable improvements. This program was based on a consistent standard developed by the leaders in manufacturing excellence –the Society of Manufacturing Engineers (SME), the Association for Manufacturing Excellence (AME), the Shingo Prize for Excellence in Manufacturing. The certification program modeledMROprocesseswithinthecompany to accelerate participant learning.

Clients

client >

Coherent, Inc.

company profile >

World’s leader in Photonics, supplying laser systems, components, laser mea-surement, control products, and preci-sion optics to over 80 countries

Value Stream Mapping helps drive significant operational improvements.


Coherent’s global operations leadership team wants to continue to build a culture that is based on execution and commitment to results, fostering a team dedicated to high standards of quality, leading edge technology, and continuous improvement.

The Coherent global leadership team engagedManextohelpinstituteLeanaspart of the company’s best practices by evaluating key opportunities of improvement within the Santa Clara facility.

results delivered >

The comprehensive Value Stream Mapping and roadmap of the Santa Clara operation haveledtothefollowingresults:

• Improved collaboration with Material Management, Planning, and Manufacturing• ReducedleadtimeintheRLSvaluestreamfrom9daysto7days (22%improvement)• Establishedflowmanufacturingthrough enhanced material planning, better supplier communication, and consolidation of work areas

approach >

Manex helped the global operations leadership team in Santa Clara implement operational process improvements using a systematic,holisticLeanmethodology.

A three-phased approach was used to focus on rapid implementation based on near-term opportunities.

•PhaseI:Assess(ValueStreamMap)•PhaseII:Design(Implementation Roadmap)•PhaseIII:Implement(Kaizen Implementation)

Clients


WithPowerLight’srapidgrowth,management was looking for ways to improve operational performance by reducing operating costs and improving overall productivity with the implementation ofLeanPrinciples.

results delivered >

The broad adoption of these practices has resulted in the following performance improvements:

•Over20%reductioninwork-in-process inventory•20%reductioninleadtime•20%immediateproductivity improvements• Improved employee empowerment

approach >

ManexhelpedPowerLightimplementoperational process improvements by delivering a one-week Kaizen Blitz based on5SPrinciplesandVisualControl.Through in-depth simulations, the PowerLightteamlearned5Smethodsinstrumental in identifying wasteful activities throughout the organization. With this new knowledge, the company has organized two additional Kaizen events and made a considerable impact on productivity.

client >

PowerLight Corporation

company profile >

Nation’s leading designer and installer of grid-connected solar electric systems and energy efficiency services

5S methods widely adopted for productivity gains.

Clients


NorthropGrummanusesathoroughPerformance Appraisal System to ensure their employees operate at the highest levels in the industry. The management team of the Electronic Systems facility wanted to ensure that their employees exceeded the performance factors laid out in the appraisal system.

results delivered >

With the use of this program, employee turnover was significantly decreased with all of the trained employees continuing their careers as leaders in the organization (0%turnoverrateamongtrainedemployees). Overall, employee relations, communication, and teamwork improved across the facility as the trained employees used the tools and techniques learned in the program which ultimately increased productivity.

approach >

Manex partnered with the University of Santa Cruz Extension in developing and delivering a comprehensive leadership and management training program that addressedNorthropGrumman’ssevenleadership factors — use of judgment and initiative, employee coaching and development, teamwork and process improvement, communication, personal effectiveness, framing strategy, and customerfocus.35keyemployeesandmanagers were trained in these areas, significantly improving their overall performance and commitment to results.

client >

Northrop Grumman Electronic Systems

company profile >

World leader in the design, development, and manufacture of advanced electronics for military, civil, and commercial use

Management training helps new division develop and retain key employees.

Clients

Clients

client >

T.G.I.F. Body Shop

company profile >

Full service auto repair business that provides timely collision repair services using the latest technology and continuing education delivering the highest levels of customer satisfaction and quality

In-depth workforce development program drives productivity and enhances competitiveness.


OneofthechallengesthatT.G.I.F.BodyShop is faced with is to become more efficient in an ever demanding industry which is in a technician shortage crisis. The continuing education of their employees is part of their plan to ensure high levels of customer satisfaction through the consistent delivery of superior quality services. The owners turned to Manex to enhance their employee skills and make the business more efficient by implementingLeanprinciplesincludinga5SWorkplaceOrganizationsystemandVisual Factory.

results delivered >

Significantresultsinclude:

•Increasedsalesby$500,000• Retainedsalesby$50,000• Workforcedevelopmentof$15,000• Increasedemployeemorale

TheownersofT.G.I.F.BodyShophavecontinued to engage Manex in the development and implementation of their continuing education program for their employees. Manex is currently providing training on a number of different projects.

approach >

ManexdevelopedacomprehensiveLeantrainingprogramthatincluded:

• Phase I - 7 types of waste, employee empowerment, standardized work•PhaseII-5S,VisualFactoryandKaizen• PhaseIII-Implementationof5Sand Visual Factory on the shop floor and in the office• PhaseIV-Currentstateprocess mapping, brainstorming, and future state mapping

Clients

client >

Wilkinson Manufacturing

company profile >

Precision machine shop (metals and plastics) providing product development, prototyping, short-run production and full production services to customers in the building and semiconductor industries

Optimized facility layout improves throughput by 30%.


Wilkinson Manufacturing is currently locatedina5500squarefootrentedfacility and is planning to move to a new 8500squarefootownedfacilitytoprovidethe opportunity for a more functional layout and room for growth, along with projecting a more professional image to current and prospective customers. An inadequate layout can be highly detrimental to productivity and consequently profitability.

Wilkinson engaged Manex to assist in reaching their objectives for this new facility

results delivered >

Continuous, efficient flow patterns of materials, personnel and information were implemented using consistent and repeatable processes. Significant results include:

• Improved collaboration across the manufacturing team•30%improvementinthroughput•20%reductioninlaborcosts• Workforce development improvements of$44,000

approach >

Manex worked with Wilkinson Manufacturing using a holistic, systematic approach to develop an efficient flow for the new facility.

Keyelementsincluded:• Optimizing “flow” and work cell layout in thenewfacility(receiving/shippingand production areas)• Improving and sustaining workplace organization at the new site•Improvingproductivityandquality/yield• Providing a foundational understanding and initial implementation of lean manufacturing

Clients

Operational efficiencies lead to 30% improvement in on-time-delivery.

client >

Max Machinery, Inc.

company profile >

Leading manufacturer of precision flow meters and components for the aerospace, semiconductor and medical device industries.

results delivered >

MAX dramatically increased production levels, reduced annual operating costs, improved quality and improved time to market. MAX is positioned to exceed its operational requirements and achieve ISO 9001:2008certification.Specificresultsinclude:

• 50%improvementincycletimewith $20K/yearincostsavings• 30%improvementinon-time-delivery• 22%improvementinfirst-pass-yield• 30%reductioninrework• 35%reductionin‘over-processing’• 40%reductioninfrontofficecycletimes• Improvedqualityandscheduling

approach >

Manex used a proven, tailored approach consisting of a detailed process map of the operations from order entry through shipping with a roadmap for improvement. Actualactivitiesincluded:

•Creationofcurrentstateprocessmaps•ImplementationofprovenLean Manufacturing principles•ImplementationoftwoKaizenEventsalongwithPracticalProblemSolving&RootCauseCorrectionAction(RCCA)•Applicationof6-sigmaDMAICProcess•CreationoftheISO9001:2008quality manual and supporting documentation


As Max Machinery continues to focus on providing high quality solutions to its customers'needs,themanagementteamisproactivelypursuingISOCertificationtoaddress client demand and competitive pressures in the marketplace. Manex was asked to develop a comprehensive review of the operations and develop and implement plans that would immediately improve the company’s operations and cost structure and prepare the company forISO9001:2008certification.

Clients

Implementation of Lean Manufacturing results in 20% reduction in lead times.

approach >

The project consisted of 3 parts which included,StrategyDevelopment,SalesForceEffectivenessandLeanManufacturing.Specificstepsincluded:

• Identifying the company’s ideal markets by developing hi-impact marketing messages and collateral• Altering the sales process by adding hi-impact facts and figures, allowing buyers to realize true long-term benefits• ImplementingLeanManufacturingto identify and resolve key differences in the manufacturing process• Reductioninleadandcycletimes


The company was finding itself in a commoditized space with declining sales. They were experiencing a continual decline in the number of opportunities in the marketplace.

client >

Goodwin-Cole Co.

company profile >

Manufacturer of products made from natural or synthetic textile fabrics, including awnings, canopies, tents, flags and industrial textile products

results delivered>

The broad adoption of these practices has resulted in the following performance improvements:

• Increased sales close rate •Developedmorethan60viableleadsfor the company to pursue•Reductioninleadtimesby20%• Cycletimereductionof40%

Clients

Implements world-class Lean Manufacturing to gain 32% in additional capacity.

approach >

Manex used a tailored approach designed to maximize the available floor space, improve time to market on all products and ensure the company had sufficient capacity tosupportthecompany’s5-yeargrowthplan.Maneximplementedthefollowing:

• 5-yearsalesgrowthplan• “Machine uptime” improvement plan to meet capacity needs • Current state and future state maps and layouts to optimize shop floor operations • 5SandLeanManufacturingprinciplesto reduce costs and defects, and improve profitability


Cellotape’s strategic acquisition of a competitor resulted in two divergent operations with an overlap in administrative functions. The company’s executive management team wanted to evaluate the consolidation of both locations into one site and implement operational improvement through the utilization of lean manufacturing. In addition, Cellotape wanted to improve its total operational effectiveness, reduce costs and improve the"timetomarket"fordesigninganddelivering their innovative labels.

Client >

Cellotape, Inc.

company profile >

Leading manufacturer of high quality labels for the Consumer Packaged Goods Industry

approach >

Cellotape dramatically increased productionlevels, reduced annual operating costs, improved quality and time to market. Specificresultsincluded:

Over$600kreductioninoperatingcosts• 35%improvementinmachineuptime• Consolidation of plant operations resultinginover$1.2millioninsavings• 80%reductioninnonvalueaddedwalk time for inspectors • Reductioninorderentryprocessby35%• 34%reductioninleadtimes• 45%reductionincostoflabels• Reductionoftotalenergycostsby35%

Clients

client >

Pacific Biosciences, Inc.

company profile >

Genome sequencing company developing a transformative singe-molecule DNA sequencing platform

Lean transformation drives a 500% increase in throughput.


As a high performance organization, PacBioidentifiedLeanManufacturingasacritical way to achieve their strategic objectives of increasing price performance andoverallcapabilitiesinreal-timeDNAsequencing.

PacBio turned to Manex as a partner to transformtheirorganizationusingLeanManufacturing because of Manex’s holistic, collaborative approach, comprehensiveLeanknowledge,andin-depth manufacturing expertise.

results delivered >

TheimplementationofLeanhashelpedtheorganization improve productivity and increase the efficiency of its opertions. Specificresultsinclude:

•40%increaseinproductivity• Reducedfloorspacerequirementsby >50%,eliminatingneedfornewbuilding• DoubledthroughputinSurface Production• Reducedcycletimeby68%• Consolidatedtwo“manufacturingareas” into one area without any downtime•ProvidedcomprehensiveWorkforcedevelopmentthroughLeanManufacturing training

approach >

Manex developed this three-step process designed to achieve PacBio’s aggressive process optimization and operational improvementtargets:

• TeachtheConcept(TC)–PacBio’s employees were trained in the concepts ofLeanManufacturing• ProvetheConcept(PC)–Trainees participatedinLeansimulationexercises• ImplementtheConcept(IC)–PacBio’s team identified opportunities to improve production processes, including a current state map, a future state map and then the requisite steps to attain the future state

Clients

Reduction in changeover time by 91% with additional capacity of $2.6 million per year

results delivered >

Dramaticallyreducedsetup/changeovertime, increased inventory turns, implemented new scheduling system, eliminated the need for an additional warehouse, and increased throughput. Specificresultsincluded:• Reductionofchangeovertimeby91%• 40%increaseintotalyearlycapacitydue to the new scheduling system •Reductioninovertimeof$450K/year andlaborsavingsof$350K/year• Estimatedsavingsof$1Mannuallyby eliminating the need for an additional warehouse location• Improvedflow/inventorymanagement

approach >

Manex used a proven, approach designed to increase throughput and increase warehousespaceavailability.Just-In-Timephilosophy was implemented, and the facility layoutwasoptimized.Specificactionswere:•Identifyinghighimpactopportunities•Improvingthelinesetup/changeover process using a Kaizen event•Eliminatingtheneedforanadditionalwarehouselocationthroughthe‘Make to Order’ Kaizen event•DevelopingKPIstosustainandmeasure improvement•Benchmarkingreportforassessment


ThemanagementteamatLaTortillaFactory recognized that in order to remain a leader in their industry, they needed to continually improve operational and financial performance. They were specifically interested in improving their operations by increasing throughput. The company also had excessive waste as part of their value stream, leading to high inventory levels. This led management to search for an additional warehouse location to house finished goods.

client >

La Tortilla Factory

company profile >

Leading, worldwide manufacturer of high quality tortillas and wraps for domestic and international customers

Clients

New website with enhanced style, content and Search Engine Optimization (SEO)

results delivered >

With a new marketing strategy in place, Millennium Molding has the necessary tools to increase their visibility in the marketplace and increase sales and revenue.Specificresultsinclude:• New website with enhanced style and content and improved SEO • Marketing materials for sales meetings• Databaselistofmorethan35,000leads• Improved closure rate of sales calls• AnticipatedsalestoCalTrans,HOAs, nurseries, other privates companies, retail, etc.• Anticipated$600kinsales,translatingto 3.1millionpoundsofrecycledrubber

approach >

Manex helped Millennium Molding differentiate itself in the marketplace, using its unique “engineered solutions” capabilities andbusinessmodel.Specificstepswere:• Established marketing strategy• Conducted market research and identified opportunities • Developeddatabaseoftargetcustomers• Revampedmarketingmethods/materials• Developedsalescapabilities• Produced actual sales opportunities • Created high performance website (SEO)• Provided Content Management System • Rebrandedwithhigh-impactmessaging


Millennium Molding was interested in developing a prioritized strategic, marketing plan to determine which companies/segmentstopursue,evaluatethe best way to engage prospective buyers and take advantage of existing market opportunities.

client >

Millennium Molding

company profile >

Contract manufacturer of plastic, rubber and composite parts, specializing in recycled materials

Clients

client >

Biotech Firm

company profile >

Developing an inexpensive, fast test for infectious diseases, targeted to serve the needs of developing countries in Africa and Asia

Automation dramatically improves productivity to scale for high volume production.


This biotech firm applied and received approvalforassistancethroughNIH’sSBIRManufacturingAssistanceProgram.

In anticipation of demand and production requirementstomeet100,000unitsofproductionpermonth(from10,000),thecompany engaged Manex to review and understand their current manufacturing processes with the objectives of identifying bottlenecks, opportunities for improvement and/orautomation,andcriticalControlPoints from a quality perspective.

results delivered >

Specificproductivityimprovementsinclude:• Reducedtheamountoflaborrequiredin the test strip manufacturing process by 30%• Improvedthroughputinthereagent copperandthereagentfillerby40%• Improvedthroughputby40%ofthe conjugates into tubes with vision verification of presence for correct color and number• Workforcedevelopmentimprovements of$10,000

approach >

Manex used a comprehensive approach to document the current manufacturing process, analyze and synthesize opportunities and identify critical control points (CCPs), • ReviewofCurrentManufacturing Operations – the development of a current state process to identify manufacturing bottlenecks, CCPs and areas for improvement. •AutomationRecommendations– Key processes were evaluated providing specific recommendations to ramp for high volume production.

Clients

client >

Large Rubber Recycler

company profile >

Handles the scrap tire needs for companies across Northern California

Significant gains in the productivity, profitability and consumption of recyclable rubber.


With the accelerating growth of the scrap tire market, this large west coast recycler was looking for ways to improve their competitiveness using creative approaches to make high quality renewable products. As a recycler of scrap tires, the company gained assistance to achieve these objectivesthroughtheTire-DerivedProduct Business Assistance Program (TBAP) offered by the California Integrated Waste Management Board. TBAP provides targeted assistance to scrap tire processorsandtire-derivedproduct(TDP)businesses tailored to their unique needs.

results delivered >

The insight, analysis and recommendations provided by Manex, led to significant gains in the productivity, profitability and consumption of recyclable rubber. Specificresultsinclude:•Improvedutilizationratesto80%or higher• Improved equipment and labor efficiencyratesof80%orhigher• Identified areas to increase market penetration and revenue with specific classification of potential clients• Provided comprehensive workforce developmentthroughLean Manufacturing

approach >

As part of the Business Assistance Program (BAP), Manex assessed, analyzed and developed recommendations on a 4 component Activity Plan for the company.•FacilitiesLayout&FlowProcesses•StrategicVisioning:Tohelpdetermine the organization’s vision and metrics. • Business Case Template for Customer OrderProcess:Enabledthecompanyto select the best order for production •LeanManufacturing:Comprehensive5S training with supporting Kaizen events

Clients

client >

Cultured Marble Products

company profile >

SF Bay Area leader in the manufacture of custom-made Cultured Marble, Granite and Onyx fixtures

Productivity increases significantly by 78%.


Cultured Marble Products (CMP) engaged Manex to analyze ways to improve upon its operations on the manufacturing floor and in the back office, while simultaneously providing training to its employees. These activities will be instrumental in enabling CMP to improve upon its efficiencies, achieve higher levels of profitability, and ultimately produce better products for its customers.

results delivered >

This systematic approach has led to the identification and implementation of process improvements and standard work practicesacrosstheoperation:

• 134%improvementin5Sscorefrom Jun07–Jun08• 78%improvementinproductivity• 20%reductioninscrap• 51%reductioninremakes• 76%reductioninrework• Workforcedevelopmentimprovements of$290,000

approach >

To achieve these objectives, Manex tailored a phased approach with the CMP management team.• ProductFlowObservations& Recommendations• Product Flow Improvement Implementation• BackOffice/FinanceFunction Observations&Recommendations• EnergyAuditandRecommendations• Continuous Improvement Activities and ETPGrantSupport• Additional Consulting and Training

Clients

Approximately $30,000 of time saved per harvest.

results delivered >

The streamlined process and new mobile harvest inventory tracking system will allow SVI to operate more efficiently which will result in significant cost savings.

Specificresultsinclude:• Approximately$30,000oftimesaved per harvest season with implementation of new mobile harvest inventory tracking system• Approximately$400,000oftimesaved per harvest season with additional opportunities for improvement identified in the project

approach >

ManexassistedSVIwiththefollowinggoals:

•Calculate efficiencies gained through the deployment of a new mobile harvest inventory tracking system• Definefurtheropportunitiestoincrease efficiencies, enhance communication, and drive costs down throughout the harvest operationManexdetailedtheSVIHarvestProcessona‘ProcessMap’andidentifiedareasforstreamlining with specific, realistic improvements. These were mapped and compared to the current state to calculate the relative cost savings.


Duringthe2011harvestseason,SVIprovided access to their facilities, personnel, and operations in order for Manex to understand the harvest aspect of vineyard operations. In exchange, Manex provided consulting services to SVI in order to help them improve harvest operations.

client >

Scheid Vineyards

company profile >

Winery in Monterey County with 13 distinct vineyards, supplying grapes for wineries in California


Galaxy’srapidandcontinuinggrowthresulted in a move to a new production facility. The executive team was interested in implementing continuous improvement initiatives as a precursor to its anticipated expansion, as well as a foundation for employee knowledge and skills to drive its continuedgrowthandprofitability.Galaxywanted to explore operational improvement opportunities in its croissant line and packaging areas. Manex was asked to assist in identifying and implementing those opportunities and providetrainingofGalaxyemployees.

results delivered >

As a result of these continuous improvementinitiativesGalaxyDessertsdramatically increased production levels within the croissant line. With improved operational flow and production personnel fullytrained,theGalaxyteamcanmoreeffectively meet their profitability and growthobjectives.Specificresultsinclude:

•Improved flow with new layout•Increasedthroughputby100%•Reducedperunitcostby20%

approach >

Manex used a proven, tailored approach designed to maximize production efficiency and quality, and to involve production personnel to the greatest extent possible. The team focused specifically on the existing croissant line and existing packagingarea/teamtodrivehigh-impactresults, within these two critically important areas.Thetailoredapproachincluded:

•ValueStreamMapping•InitialImplementationand“Tuning”•Follow-up•WorkforceDevelopmentSupport

Clients

Improved operational flow increases throughput by 100%.

client >

Galaxy Desserts

company profile >

Worldwide leader in individual desserts; developing, manufacturing, and distributing company-branded and private-label high-end unique dessert items

Clients

client >

Crossfield Products Corporation

company profile >

World-class manufacturer of quality, fluid-applied industrial flooring, waterproof decking, marine decking and decorative concrete overlays

Holistic approach drives 24% growth in sales.


Withasharpincreaseinsales,Crossfield'smanufacturing capabilities were stretched to meet this increasing demand. Crossfield was now looking for a way to concentrate on operational excellence to help grow the business and increase revenue even more.

The management team turned to Manex to assess the current manufacturing operations and identify opportunities for improvement from order entry through shipping.

results delivered >

With the implementation of this comprehensive roadmap, Crossfield is well on its way to achieving operational excellence with significant impact to the company’stopandbottomline.LeanManufacturing lies at the heart of these measurable improvements.

• 24%growthinsales(yearoveryear)• 45%reductionincorematerialscosts• 11%improvementinon-timeshipments• 2 day shorter lead times

approach >

Using a holistic approach, which included a detailedassessmentconsistingof12keybusiness metrics benchmarked against leading companies in the coating industry, Manex developed a roadmap to help Crossfield prioritize activities to support and achieve their short and long term business objectives.

Leanwasusedasthefoundationforcontinuous improvement. Manex trained the workforcein5Sandtheteamimplementedprocess improvements and eliminated bottlenecks throughout their operations.

Clients

client >

Gayler Construction, Inc.

company profile >

Premier Design/Build firm that specializes in residential and commercial remodeling and construction projects

Millions in new business within 60 days of the close of the project.


Since the real estate decline, construction and remodeling projects have decreased markedly, requiring construction firms to increase their proactive outreach efforts. Gayleridentifiedtheneedtorefineitsprocesses in acquiring new business opportunities (leads) while increasing the capture rate of those leads. The company turned to Manex to facilitate strategic management sessions to identify specific activities to increase revenue.

results delivered >

As a result of these facilitated sessions, the Gaylermanagementteamidentifiedcriticalways to weather the soft real estate market by repositioning their value proposition to the industry with a focus on their key differentiators.

•Qualifiedleadshavedoubled• Closeratehasincreasedbymorethan 75%(from28%toover50%)• Millionsinnewbusinesswithin60days of the close of the project

approach >

Manex provided a series of facilitated sessions to identify high-impact activities the Gaylermanagementteamcouldimplementto increase revenue. These specific activities were focused on lead generation and improving the close ratio of these leads.

• Clarify targets (revenue, growth, number of accounts)•Leadgenerationandmethodsto capture all sales opportunities• Methods to identify leads• Metrics and measures

Clients

Increased throughput and efficiencies results in multi-million dollar OEM contract.

results delivered >

SpecificResultsincluded:

•Approximately15%to20%reductionin costs for order entry processing through the implementation of the action plans•Anticipatinga10%to12%reductionin costs on the production floor by eliminating waste (over production) •Approximately30%reductionintotal inventory by reducing the amount of work in process between areas• Secured new contract worth up to 7 milliondollarswithFortune50OEM

approach >

Manex assessed the production environment to create a prioritized roadmap for“quickkit”improvements,usedLeanManufacturing processes to increase efficiencies, improve the flow of materials, improve quality and decrease lead times.

• Trained7teammembersin5S,Practical Problem Solving and • Implemented two high level PPSs programstosupporttheCATSQEP• Assisted in the re-layout of the office to facilitate an error-free order entry system• Created a Kanban replenishment system in the finished goods area


The management team was proactively pursuingtheimplementationofLeanManufacturing in their Santa Ana operations. InsulTech asked Manex to design and implement a mentoring program for key operations employees, with the objectives of increasing process efficiencies, improving the flow of materials, reducing rework, eliminating errors and maximizing customer order performance.

client >

InsulTech LLC

company profile >

Leading manufacturer of high quality insulating products used in automotive, industrial, and aerospace products


Z-World was experiencing phenomenal growth(over30%annually),placingextreme pressure on the manufacturing operations to meet these customer demands effectively.

results delivered >

An environment of continuous improvement was developed as the manufacturing operation embraced the strategies and tools shared by Manex. Specificresultsinclude:

•Receiving/Inspection—Improved workflowby30%•FinalTest—Obtained80%improvement in locating testing units•WaveSoldering—Achieved50% efficiency improvements

approach >

Manex assisted the management team in re-engineering their manufacturing processes with the comprehensive implementationofLeanPrinciples.Tobegin the transformation, a two-day Kaizen EventwasheldwiththeOperationsGroupManagementteamandstaff.LeanPrinciples,ValueStreamMapping,and5Smethods were employed with the team to identify areas of improvement. Once identified, Manex then worked with the manufacturing team to implement these changes, streamlining processes and improving productivity.

Clients

client >

Z-World

company profile >

Pioneer in the embedded controls industry, providing high-performance, reliable, embedded control solutions

New Lean culture drives manufacturing productivity improvements.


With heightened demand and intensified competition, Westcor, a division of Vicor, was looking for ways to simplify and streamline its manufacturing processes of morethan800modelsofconfigurablepower supplies.

results delivered >

Westcor improved operational performancewithsignificantresults:

•80%improvementincycletime•71%reductioninwork-in-process inventory •$80,000-$120,000inlaborsavings•35%increaseinavailablefloorspace•$18,000savingsincapitalequipment• Established a new culture of employee motivation, involvement, and empowerment.

approach >

To increase quality controls and simplify assembly methods, Manex introduced LeanManufacturingconceptsusinga five-daycellular/flowKaizenEventthatincluded immediate hands-on participation of the manufacturing line. Within the event, the overall work area was re-engineered to improve cycle time, work-in-process inventory levels, workflow balance, and access to parts. This resulted in the freeing up of capital equipment in two lines and the elimination of three workstations (from eight to five).

client >

Vicor – Westcor Division

company profile >

Designs, manufactures and markets modular power components and complete power systems used in the communications, data processing, industrial controls, test equipment, medical, and defense electronic markets

Streamlined manufacturing process leads to substantial operational efficiencies.

Clients


C&HSpecialistswasfacingintense pressure to boost productivity and improve on-time delivery performance in order to remain competitive.

results delivered >

On-time delivery performance improved significantly with the use of these tools and processes. In the first month alone, on-timedeliverywasincreasedfrom54%to78%,whilecompany-wideproductivityincreasedby30%withinthefirsttwo quarters. Intrinsic to these improvements was a new sense of employee empowerment and team effectiveness.

approach >

Manex developed a flexible programusingLeanPrinciplesand5Smethods to deliver immediate and measurable results to their bottom line. All team members within the critical manufacturing departments — Inspection, Shipping,andReceiving—weretrainedin5SmethodsandLeanManufacturingtoidentify areas affecting productivity and implement new processes to improve operations. Tools and metrics were implemented across the departments.

client >

C&H Specialists

company profile >

Provides manufacturing support in the fields of electromechanical assembly, sheet metal fabrication, and frame construction, serving contract manufacturers globally

Empowered employees boost productivity.

Clients


Advanced Material Solutions (AMS) was struggling with material shortages and excessive defects in supplier parts. As a result, productivity was hampered causing AMS to fall far short of their production goals. To make matters worse, profitability was also suffering from poor management of Purchase Price Variance (PPV).

results delivered >

With the implementation of the improved supply chain processes, AMS was able to dramatically increase profitability and improve productivity. Specific results include:

• 90%on-timedeliveryimprovement•66%PPVFlowimprovement•20%salesincrease•$500,000inventoryreduction•$150,000laborcostsavings

approach >

Teaming with AMS, Manex designed and delivered a comprehensive supply chain management program. Manex developed and deployed a five-week program, implementing re-engineered processes that eliminated parts and assembly receiving problems while improving the PPV process flow with a systematic approach. With better control of parts, the manufacturing line consistently met deadlines.

client >

Advanced Material Solutions (AMS)

company profile >

Leading provider of customized turnkey electronic manufacturing services

Reengineered supply chain increases productivity and profitability.

Clients

Clients

ISO Certification leads to highest levels of quality for productsand services.

results delivered >

Operational efficiencies were gained with the development and implementation of a robustQualityManagementSystembasedon ISO90001:2000. Specific results include:

• ISO90001:2000certification• QualityManagementSystemwith documented procedures for all critical processes • Comprehensiveprocedurestoensure corrective action is taken when defects occur• Better process control and flow resulting in improved product reliability• Greateremployeequalityawareness


Faced with competitive pressures in the marketplace and increasing customer demands for more stringent quality standards,theSequoiaBrass&Coppermanagement team determined the need to implementarobustQualityManagementSystemusingISO9001:2000asitsfoundation.

With ISO certification, customers will be reassured that the company continues to deliver on its commitment to the highest levels of quality for products and services.

client >

Sequoia Brass & Copper

company profile >

Supplier of nonferrous metals in plate, bar and sheet form to the metal fabrication industries in Northern California

approach >

Manex assisted in the development of a quality management system using ISO9001:2000astheunderlyingframework.

• Identified and mapped organizational processes• Developedorganization’squality objectives, policy and system• Trained employees on the quality system and procedures for future training •Established, implemented and documented procedures and metrics for critical manufacturing processes• DevelopedaQualityImprovement program for quality and reliability

Clients

Quality Management System leads to operational efficiencies.

results delivered >

Operational efficiencies were gained with the development and implementation of a robustQualityManagementSystembasedon ISO90001:2000. Specific results include: • ISO90001:2000certification• QualityManagementSystembasedon ISO90001:2000 • Betterprocesscontrolandflowresulting in improved product reliability• In-depthtrainingandeducationof26key process owners• Systemtoconsistentlymeasurequality• Workforcedevelopmentimprovements

approach >

DevelopmentofaQualityManagementSystem based on ISO90001:2000 as the underlying framework.

• Identified and mapped organizational processes• Developedorganization’squality objectives, policy and system• Trained employees on the quality system and procedures for future training •Established, implemented and documented procedures and metrics for critical manufacturing processes• DevelopedaQualityImprovement program for customer satisfaction, quality and reliability


To deliver on the company’s high quality standards and service promise, ATP engaged Manex to assist in the implementationofarobustQualityManagementSystemusingISO9001:2000as its foundation. ATP strived to better manage its processes and foster teamwork by clarifying roles and responsibilities, ultimately driving productivity through process optimization.

client >

Applied Thin Film Products

company profile >

Leading provider of microwave components and thin-film printed circuit boards to the semiconductor industry

Clients

client >

Morgan Hill Precision, Inc.

company profile >

Job/Machine Shop specializing in the fabrication of components for a variety of materials including aluminum stainless steel, copper, brass, and plastic

Robust Quality Management System significantly reduces customer complaints by 50%.


AsMorganHillPrecision,Inc.continuestofocus on providing high quality solutions to its customers, the management team wanted to proactively pursue ISO Registrationtoaddressclientdemandandcompetitive pressures in the marketplace. ThemanagementteamofMorganHillPrecision engaged Manex to help them establish an effective quality management systemandpursueISO9001:2000Certification.

results delivered >

Specificresultsinclude:

• Throughthisrigorousapproach,the CompanygainedISO9001:2000 certificationinMay,2008• Effectiveequipmentmaintenancehas eliminated downtime completely for the last two months• Productcomplaintshavebeenreduced significantlyby50%• Thecompanyhasmetplanned objectives and metrics for First Pass YieldandSupplyOTDconsistentlyfor four months since Certification

approach >

ManexassistedMorganHillPrecisioninthedevelopment of its quality management systemusingISO9001:2000astheunderlying framework. A flexible program was designed to effectively train the staff while minimizing disruptions to the business. Using a balanced approach, Manex ensured the organization had the skills necessary to effectivelymaintaintheirQualityManagement System going forward.

Clients

client >

Cholestech Corporation

company profile >

Provides easy to use, accessible diagnostic tools and information to health care practitioners in over 35 countries around the world

Team enhances skills through customized workforce development program.


Cholestech is a competitive organization focused on helping people live longer, healthier and more active lives, their passion is people - the people who benefit from their solutions and the people of Cholestech who make it all happen.

With this strong concentration on their people, Cholestech recognizes the importance of developing the skills of their workforce. As part of this effort, Cholestech engaged Manex to enhance their team’s skills in business communications and experiment design.

results delivered >

Using a blend of classroom instruction, practical exercises, and real-world examples, employees improved their business communication and experiment design skills.Specificresultsinclude:

• 24 employees trained• Workforcedevelopmentimprovements of$20,000• Increasedemployeemorale• Improvedemployeeperformance• Improvedemployeeteamwork

approach >

Manex developed a customized training program tailored to the needs of Cholestech. The program consisted of two courses focused on improving business communications skills and a third course on experiment design. Each of these courses was delivered by professional trainers with extensive experience in each respective discipline.

Clients

client >

Laird Manufacturing

company profile >

Leader in the manufacture, sale and distribution of equipment designed for the cattle industry

Increased productivity by 19% in one of the most critical manufacturing processes, pre-fabrication.


Lairdhasgrowndramaticallyoverthepastseveral years, achieving a significant average annual growth rate of twenty percent. To support this phenomenal growth, the company is committed to shaping an organization with a shared culture and streamlined, efficient operations built on a foundation of quality, leading-edge technology and continuous improvement.

results delivered >

Lairdgainedsignificantimprovementsinone of their most critical manufacturing processes, pre-fabrication. Specificresultsinclude:

•71%improvementinsafety•17%reductioninrework•19%immediateproductivity improvements•29%improvementin5S• Workforce development improvements of$30,000

approach >

ManexassistedLairdinbuildingastrongfoundationofLeanusingaprovenadvisoryapproachandemployingaworld-classLeanEnterprise Transformation model. Manex carefullyassessedLaird’sbusinessandprocesses, identified opportunities for improvement, and then facilitated the implementation of those processes throughout the organization.

Contact Us

To find out more about how Manex can help you assess your current situation and develop a roadmap for the future, please contact us:

ManexThe Corporation for Manufacturing Excellence2010CrowCanyonPlace,Suite320SanRamon,CA94583

1.877.33.MANEX

www.manexconsulting.com

Documents

Manex Services, Consultant Overview and Project Highlights