MSI Lean Manufacturing

MSI subscribes to lean manufacturing as the primary standard for developing and refining our processes. Lean manufacturing is a production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and something to be eliminated.

In other words, lean manufacturing is centered on preserving value with less work. This, in the end, lowers costs, speeds overall production and contributes to improved quality. It does this by optimizing workflow, employing a policy of continuous improvement to make production almost alive; growing with the changes that all contribute toward the goal.

At MSI, we are always seeking ways to reduce waste that results from:

  • Transport/material flow
  • Inventory
  • Motion
  • Waiting
  • Overproduction
  • Over processing
  • Defects

Every innovation is customer-driven

MSI’s customer demand for a reduction in mold delivery time drove the re-definition of our manufacturing process through the use of an incremental approval system that begins with mold concept and continues through final design. Incremental approvals speed the flow of production beginning as early as 48 hours following receipt of the part database and continue throughout the design and manufacturing of each mold.

The combined success of MSI Mold Builders’ manufacturing and engineering teams is due to our focus on quality that drives our entire process. This proven process depends on thorough inspections following each manufacturing phase, which insures reduced costs and compressed lead-times. It is through consistent monitoring and the identification of opportunities that allow our manufacturing teams to implement changes rapidly.

The MSI Quality Process

MSI Mold Builders' customers realize the benefits of our advances in Lean Manufacturing, Six Sigma,

and 5S processes at its facilities.  We pride ourselves in being a very process-driven organization, working to maximize efficiencies in all aspects of the business.  From the request for quote to the finished mold shipping, we work to do things in the best way possible to assure customer satisfaction.  Being a process-driven company helped us achieve our ISO 9001 certification in 2010.   

The MSI process has been designed and improved over the years to provide the structure to yield consistent results for meeting customer expectations and requirements, while remaining able to adapt to the unique needs of each customer and each project.  We track many customer satisfaction metrics to make sure we are making progress towards enhancing our customers’ experiences.  

Our process is intended to get the best information upfront as early as possible, allowing for good decision making in design and manufacturing from then forward.  It is much less costly, in terms of dollars and timing, to solve a problem in the beginning vs. catching something at the end of the build.  From the start of a new mold build, we do a data review to check out the part models and point out any issues or improvements that can be made.  We work with our customers to resolve these before we get too far into the design process.  

From approved data to design and build, MSI uses incremental checks and reviews throughout the design and manufacturing process.  This ensures that a problem is caught as soon as possible.  Cross functional teams review the designs at different stages prior to the customer reviewing them.  

Once the design is released to manufacturing this attention to detail continues throughout the production process.  As each block travels through the manufacturing process, there are checks to ensure that it will meet both the expectations of the customer and also the expectations of the next department to receive the block.  This continues throughout the entire production process all the way to sampling and the complete mold audit.