Make your lab More eff icient and profitable

with Lean products & services froM whip Mix

T H e L e a n a d va n Ta g e

whip Mix and its team Members have received state and national recognition awards in the past few years for our successes in the implementation and use of lean tools within our organization. but, back in the 1990’s, whip Mix and other manufacturers were facing strong competitive pressures in both the domestic and international markets. Profit margins were eroding, finding qualified Team Members was becoming harder and the finished product quality as well as order fulfillment delays were trending in the wrong direction.

Our leadership embarked first on a journey of introducing TQM concepts and tools to our entire workforce. the leadership team learned and taught (and still teaches) these skills. our results were good, but not “world class”. So we next used the ISO 9001 Quality System as a template to standardize all our processes from product design to order entry to purchasing to productions and so on. again—while our results were good, we still seemed to be too focused on our internal processes without enough customer focus.

by 2001, we realized that the lean process pioneered by toyota in Japan could provide whip Mix a better link to knowing what our customers want. by focusing on customer wants, we could eliminate waste (defined as anything the customers will not pay for) and thus lower our costs, improve profit margins, minimize price increases, meet delivery dates, gain market share, reward team members involvement and create a roadmap to guide our product development activities.

i am pleased to say that our success has resulted in several awards, but i am proudest of the bonds we have forged between our team members and our customers. let us know how we can help you.

sincerely,

allen F. Steinbockceo & chairman

whip Mix corporation

T H e W H i p M i x L e a n a d va n Ta g e

Lean is about having the right material,

the right equipment, in the right place, at the right time,

clean, operational, and ready to use.

Sharing Our Lean Success whip Mix is working diligently to help our dental lab customers work lean by providing the proper material and equipment, and consulting with them to ensure they apply and use the principals and disciplines of lean Manufacturing. Whip Mix Corporation is dedicated to: • developing and delivering material and

equipment that is designed to speed up the lab process, eliminate waste, and help you provide maximum value to your customers with the finished product.

• Providing financial and practical tools to analyze industry changes, and ensure the desired return on investment in new materials or technology.

• consulting with and assisting the lab team members to understand and use the right lean tools in their kaizan events or process improvement projects. Tools such as a 5S project, value stream Mapping, cellular design, or poca-yoke (error proofing).

The following pages show how 5 labs have benefited from the Whip Mix Lean Advantage progam and how whip Mix products have improved their operations. to see how your lab can benefit contact:

Robert e. Long lab trade relations Manager whip Mix corporation502-634-5335blong@whipmix.com

p R O p R e S S S ppressing furnace

• presses 2x faster than conventional pressing furnaces

• Minimizes or prevents a reaction layer

• delivers successful presses even when cracks are detected

• ensures consistent and dependable pressing results

“ Lean manufacturing dictates that all of our equipment meets precise performance standards. Nowhere is that more important than in our pressing operation. We have been using the ProPress SP furnace for over 13 months and have not had a single miss-press.”

C R e aT i v e e x p R e S S i O n S d e n Ta L L a B O R aTO R y

our laboratory implemented lean Manufacturing in 2009 as a process to eliminate waste, improve our efficiency, shorten turnaround times, compete in the global marketplace and improve our profitability. Since then, our turnaround times have been dramatically reduced, in-lab remakes virtually eliminated and more time has become available for us to provide even higher quality restorations.

Lean manufacturing dictates that all of our equipment meets precise performance standards. nowhere is that more important than in our pressing operation. our whip Mix propress sp furnace has automatic sensors to assure complete presses and programming that ensures successful presses when cracks are detected. pressing times are significantly faster with the SP furnace, the resultant pressing is higher quality and there is considerably less reaction layer. We have been using the ProPress SP furnace for over 13 months and have not had a single miss-press. Tim Tyndall cdt creative expressions dental laboratorywinterville, n.c.

W H i p M i x . C O M

“ If you want to deliver consistent results, you need to establish consistency in your processes. There is a tremendous amount of change and the competition for market share has become fierce. If you want to be in the game today, you need to go Lean!”

d e n Ta L S e R v i C e S g R O u p dsg clearwater is a part of dental services group’s network of laboratories which has 25 facilities in North America. DSG laboratories offer their clients access to proven technologies and solutions that provide the best treatment options in the market today. several years ago, dsg began implementing lean programs throughout the network to improve quality and reduce turn-around times. In the two years since joining DSG Clearwater as the General Manager, I have experienced firsthand the positive impact Lean has made in our company and how it has benefitted our clients. Every survey I have read about why dentists change labs ranks inconsistency as the number one reason.

dsg clearwater continuously incorporates lean technologies and processes into our laboratory activities to ensure quality and consistency with every case. We are thrilled with the results we get using Whip Mix’s AquaSpense SL liquid dispensing unit. Whether we are working on complex prosthodontic reconstructions, smile makeovers, or single unit crowns, our dentist’s success is dependent on our precision. this is why we rely on AquaSpense SL to provide consistent and repeatable results with our investing. whip Mix recognized the need for lean in our industry and they positioned themselves as the leader by providing Lean equipment, products, and education. for this, we should all be thankful.

Kevin Hudi general Manager dental services group clearwater, fl

aQ ua S p e n S e S LLIQUID DISPENSING UNIT

• calculates the powder weight and accurately dispenses water/liquid

• accurate casting sizes with less finishing time

• eliminates remakes

• programmable memory for up to 15 investments

L e a n R O C KQUICk SETTING, HIGH STrENGTH DIE STONE

• Formulated specifically for small batches

• Working models ready in 15 minutes

• Scannable: models may be used with cad/caM systems

• Strength: hard with superior abrasion resistance

• rich ivory color provides clean, clear margins

• Available in Type 4 and Type 5

“ In today’s market we need to partner with companies that not only understand our business but manufacture products to help us compete.”

p e R R y & y O u n g i n C .

perry & young inc. is a full service laboratory in aurora, colorado. lean Manufacturing has changed not only the way we produce, but the way we manage our business. it has provided us a structured manner to make physical and procedural changes to our lab leading to improved service and value for our customers. we continue to seek out technological advances in materials and equipment that are instrumental in completing our Lean journey.

in today’s market we need to partner with companies that not only understand our business, but manufacture products to help us compete. whip Mix’s leanrock, with its fast set time, allows us to produce models quickly without losing quality and strength. This die stone is perfect for almost all types of restorations. We can now work in small batches to improve flow control as the cases move through their unique processes within the lab. Mike young & Mac perryperry & young inc.aurora, co

W H i p M i x . C O M

“ Part of the Lean Manufacturing is the use of machines and new technology. The Xcavator not only eliminates waste and saves you time, anyone can run the machine.

xC avaTO RautoMated divesting unit

• Ideal for divesting: - pressable ceramics - press to Zirconia - press to captek - press to metal - Metal castings

• Precise: Variable speeds to ensure proper depth of cut for any investment type

• Efficient: Place hot ring directly into machine

• Easy: Sets up in just five minutes

T H e L a B 2 0 0 0 i n C . When our laboratory started using Lean Manufacturing we wanted to find a company that would help us in this process. what we found was that whip Mix corporation was the answer. whip Mix has always been on the cutting edge of new products, new equipment and now with Lean Manufacturing helping the labs to be efficient and in turn become more profitable. Whip Mix, thru Lean Manufacturing, teaches laboratories how to eliminate waste while maintaining quality, and shorter turnaround time. We have achieved and maintained the same consistent quality that our accounts depend on from our lab.

another part of the lean Manufacturing is the use of machines and new technology. when we purchased the xcavator we did not know how our lives and the lives of our technicians would change. the xcavator not only eliminates waste and saves you time, anyone can run the machine. we have it in our model room and they take turns using the machine. if you are doing any pressing —and i know that you are—and you don’t have the xcavator, i can tell you from past experience that you are wasting time and money. we are so impressed with the product that all of our technicians would rather give up their coffee than lose this machine! once again your kentucky friends at whip Mix have made our lives easier and the xcavator meets guidelines set by Lean Manufacturing to make our laboratory more efficient.

dena and dennis Lanier, cdt the lab 2000 inc. columbus, georgia

R O La n d d W x - 5 0Milling Machine

• affordable –ideal for any size lab

• Special unique cutting tool and optimized software for detailed anatomy

• Up to 5-axis capability

• compact, easy to set-up, use and maintain

• Free software and firmware updates

• outstanding customer service & support

• 2 year parts and labor warranty

p R e C i S i O n C e R a M i C S d e n Ta L L a B O R aTO R y

In 2004 Precision Ceramics, CT Scanning and Implant Planning Center became the second laboratory in the USA to receive a DAMAS certification. We immediately recognized the benefits of having a Quality Management System in place. A natural extension of that was to investigate lean Manufacturing, and to begin implementing it into our production system. today, we are on a continuous mission to improve quality and consistency, to reduce and eliminate waste, and to maximize our efficiency. Whip Mix tools such as the AquaSpense and Pro-Series furnaces, and materials like Leanrock have been an integral and important part of that process.

as we migrate towards a fully digital environment, we use gMp’s and lean principles in our cad/caM programs as well. We have found the roland DWX-50 is a very cost effective and productive part of our machining arsenal. the small footprint of the unit helps to better compress our work space, and the quiet and clean operation makes placing the unit in close proximity to the technicians who use it practical. From a speed and efficiency perspective, the DWX-50 mills a full contour zirconia crown in about ten minutes, as opposed to 15 minutes in our German five axis mill.

Only the combination of a Quality Management System, CAD/CAM labor reductions and Lean can fulfill all three goals. Lean has added another dimension of improvement in our process speed and reduction of non-value added costs. further, by accelerating process speed, lean processes have provided faster feedback and faster turnaround for our customers. Mark Jackson precision ceramics dental laboratoryMontclair ca

“ Lean has added another dimension of improvement in our process speed and reduction of non-value added costs. Further, by accelerating process speed, Lean processes have provided faster feedback and faster turnaround for our customers.”

W H i p M i x . C O M

Whip Mix Corporation 361 Farmington Avenue

Louisville, kY 40209

Visit whipmix.com

800.626.5651

Fax 502.634.4512

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SORT remove all items from the workplace that are not needed for current job or process. “only what is needed, only in the amounts needed, and only when needed.” - reduced problems and annoyances in the work place - communication between team members is improved- Product quality is increased- nva (non-value added) activities are reduced- throughput is increased

STRaigHTen (Set in Order) keep necessary items in the correct place to allow for easy and immediate retrieval. this is the foundation for “zero” defects. begin developing layouts, procedures and equipment configurations that will mistake-proof the processes.

SHine “To be LEAN you must be clean” team leaders must inspect their areas on a daily basis. if we are clean at the end of the shift we will be clean at the beginning of the next shift. This also means all equipment is operating with maximum efficiency with regular preventative maintenance and cleaning.

STandaRdiZaTiOn when we develop methods to Sort, Straighten, and Shine, we create Standardization in our workplace. It means we define everything so everyone will know exactly what we are responsible for, and when, where, and how to do it. Standards must be documented and visual: - guidelines - checklists

SuSTainWe sustain when we have developed the habits of always using the first 4 of the 5S’s together on a daily basis. you need to audit processes and procedures to ensure that they work and make improvements or changes as necessary. - Make 5S part of everyone’s daily job. - create storyboards showing success. - Communicate 5S as a LEAN project. - rotate audit assignments.

By implementing the 5S’s, you will find that you can push more work through the lab in the same amount of time with the same amount of people, adding value for your doctors with faster turnaround, better quality, and predictable results.

STaRT WiTH THe 5S’S

LEAN begins by having the right thing, in the right place, at the right time, clean and ready to use.

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