Ken.lindahl@r-consultants-llc.com 
708-821-8872

Manufacturing Consultant

A Lean Six Sigma Master Black Belt focusing in Manufacturing Operational Excellence


Below is what I call the "Improvement Cycle". Inputs and Outputs in key areas of the business. ( K.L. 3.20.18)
Continuous Improvement is a culture that encompasses the below KPIs 

Ken Lindahl - Bio

I have over 20 years of manufacturing experience in the Automotive and Aerospace Industries as a Tier 1 supplier to the OEMs. I have authored and implemented many Quality Management Systems which satisfy the QS9000, IATF16949, ISO14001, AS9100 and ISO9001:2015 certification requirements. I provide the documentation, the training and the follow up for sustainability. My process is designed to empower your employees through coaching of Lean Principles. In addition, I provide anything related to the APQP process and any of the 18 elements of the PPAP submission. I am also a Lean Six Sigma Black Belt which allows me to take your data from an analytical view and have it drive real actions in manufacturing. Everything I do is clear and always data driven. Talk to me today about how I can support your company's growth, reduce your cost of quality, and put you on a solid track to success and profit.

My Analytical Approach

My services include a comprehensive review to help identify gaps and opportunities. Results will be provided in an all inclusive report that includes a project plan with timelines and a cost analysis. My individualized plans are made up of quality services that will help you get there quickly and smoothly. We can take something as small as a control plan or PFMEA creation to a deep dive into your data for statistical process analysis and control.

Industry Wide Success - My Promise to You

My work is with a large number of clients from various industries, including:

  • Automotive

  • Aerospace

  • Medical

  • Commercial Building

My vast knowledge is ready to assist you in developing a plan that solves a small requirement up to major overhauls that drive continuous improvement within your Quality Management System.


Are your teams focused on delivering the work that matters?

Companies are grappling with change across multiple vectors: from evolving market dynamics, fierce competition, and changing customer expectations, to new business models, shifting company strategies and entirely new ways of working. However, where there’s turbulence, there’s also opportunity. Innovative companies are taking advantage of these new opportunities and finding new ways to drive continuous improvement with great execution. R Consultants, is uniquely positioned to help organizations transform the way they streamline the delivery of strategic initiatives and enable their teams to do their very best work.

Managing Director Ken Lindahl, will work with you to validate your current KPIs(Key Process Indicators) or help establish new ones that can be monitored and leveraged for positive impacts to your bottom line. Eventually using those KPI goals as a focus for on-going continuous improvement. As seen in the above model by gathering data at key areas in the business we derive goals. Once goals are established we continue to gather data in a pursuit to exceed those goals. Once we exceed and sustain the desired level of performance we can then establish new goals and repeat the process. Continuous Improvement does not stop and is essential to be successful. It's a way of thinking, it's a culture. It's something R Consultants can assist any company willing and wanting to do better.

If you're looking for some smaller project help we can assist in that as well as seen below in the "Customized Work Plan".

Book a Free Initial Consultation

We have many ways to be reached. From a simple phone call to arranging a Webex, ZOOM or Teams meeting is all possible. Feel free to reach out to the following and we can arrange a time to discuss your needs:

Phone: 708-821-8872

Email: Ken.Lindahl@R-Consultants-LLC.com

A Customized Work Plan

Overcome Your Organizational Challenges

Every manufacturing business has needs when it comes to dealing with OEMs in the Automotive, Aerospace, Medical and Commercial Industries. Most companies don't have the subject matter experts they need to keep up with all the requirements. That is where we come in. With over 24 years of manufacturing operations experience in those industries along with being a certified Lean Six Sigma Black Belt there is nothing out there we cannot handle. Some of the areas of focus are:

  • Validation of Pricing - "How do we know we are winning?"
  • OEE% and Material Utilization
  • Production Scheduling MRD, ERP
  • APQP - Advanced Product Quality Planning (All Phases)
  • PPAP - all 18 Elements of the Production Part Approval Process (Capability Studies, Gage R&R, Control Plans, Flow Charts, PFMEAs, DFMEAs)
  • DMAIC Problem Solving
  • Root Cause Analysis Training
  • Design of Experiments including Taguchi Trial Setups
  • Lead Internal Auditor in IATF16949 and ISO9001:2015 - we will provide a full QMS Audit with results, including gaps and how we fill those gaps
  • We can completely implement Quality Management Systems in AS9100, ISO14001, IATF16949, ISO9001:2015

Increase Employee Performance & Accountability

Improve labor efficiency through established OEE Goals, with clear expectations we can create a performance-based rewards system. This both raises moral and improves employee retention

Improve Profitability

Find peace-of-mind by operating your business on a data-driven plan. Our manufacturing consultants will help you implement operational controls that provide reporting and drive accountability in your efforts to achieve your goals. Look at data REAL TIME (when you can do something about it) rather then after it happened and it's too late to call an audible. By watching daily, weekly, monthly reporting you are more able to react and flex when needed.

Delivering Results

After we have agreed on the "Customized Work Plan" we develop what KPI Metrics are important to your business.

The goal is always to understand "are we winning?" You should be able to go to your metrics and understand how the business is doing. We help customize the metrics with attainable goals. Attainable goals are your initial goals to start. As part of continuous improvement we strive to exceed those goals. Once exceeded and sustained over a period of time then the goal is raised and new continuous improvement efforts start over. The cycle to setting goals, reaching them, exceeding them and then sustaining is a process that is repeated over and over.

This mentality has a direct impact on your bottom line. If we are not affecting the bottom line then we are not working with the right goals. This will mean we take a step back and reevaluate our KPIs. Most likely adding additional ones that will have the impact we are wanting.


 
Specialty Consulting in the Following Areas:

Through the utilization of Lean Tools we coach teams through DMAIC Problem Solving, Design of Experiments, Taguchi Experiments, Kaizen Events and other Lean Methodologies to achieve more than ever expected. We also specialize in Manufacturing Process Optimization with a focus on Operational Equipment Efficiency (OEE) and a PDCA (Plan Do Check Act) mentality that establishes REAL OPERATIONAL GOALS (KPIs) and in turn gives TRUE OEE% Performance. This allows for a Performance Based Rewards system that will improve employee moral and retention. Let us show you the way to realize True Continuous Improvement through data-driven decision making.

Gage R&R

Having confidence in the data you are taking and in most cases providing to the customer is critical. Many decisions are made from reviewing the data. IF you are using a measurement device that has a BAD Gage R&R then that means the data is bad as well.

PDCA - Plan Do Check Act

As part of continuous improvement we use the PDCA format to tell the story. Establish your initial findings so you know where you are at. Then establish your desired outcomes and how we get there. Once there close the PDCA with end results and take credit for a job well done.

Capability Studies

Once we have established the gage to be used to take data. That being a gage which has passed the Gage R&R by 10% or better. We can then gather our data and drop it into MiniTab and establish a few things. How capable we are within the index given (Cpk, Ppk) and what our control limits of the process are. This data is critical in understanding and forecasting the potential of producing parts out of specification. It will also extend tool life by allowing you to make offsets on machining axis to stay centered in your processes while getting the most out of your tools.

Flow Charts

Add more detail to your processes by adding Flow Charts. Visual Factory is an effective way to change the culture. When people can visualize the process rather than having to read about it sinks in so much quicker. They are great for training aids as well.

This is your "Call to Action"

By leveraging R Consultants LLC for some of the specialty work (capability studies, gage R&R, problem solving, etc...) allows you to focus your attention on other things that matter. Then by utilizing our team to coach yours in Lean Continuous Improvement Methods will guarantee SUCCESS.