Lean 6-Sigma

Doing “little things” better every day is the cornerstone philosophy of Major Tool’s Lean / Six Sigma efforts. These “little things” focus on making incremental improvements to minimize non-value added efforts by eliminating various types of waste within the organization. These improvements are done via Rapid Improvement Projects, Kaizen Events, and even Six Sigma Projects. All employees are encouraged to submit their improvement ideas and they are recognized for their contributions.

From the moment you enter our facility it becomes apparent that Major Tool & Machine has a robust 6S Program. Each year, various teams throughout our organization compete for Major Tool’s coveted Gold and Silver Broom Awards recognizing outstanding 6S team efforts. Major Tool is a proud recipient of the 6S Excellence Award from the National Tooling and Machining Association (NTMA).

We employ several Six Sigma Black Belts who lead teams in identifying and minimizing causes of variation in processes, products and services within the organization. Each project is broken down into a series of DMAIC steps. DMAIC is an acronym for Major Tool’s Six Sigma methodology, which translates to Define, Measure, Analyze, Improve, and Control project phases. All employees are trained as Yellow Belts and many have also been trained as Green Belts using the DMAIC methodology. This training provides a foundation for Major Tool’s continual improvement efforts.

Major Tool & Machine is actively pursuing the tools and culture of lean manufacturing and 6 sigma process improvements. Our goals are to enhance our competitive advantage by increasing plant throughput, which helps us respond more rapidly to customers’ needs and improves profitability, and to earn recognition from key customers that we are indeed a preferred supplier.

We also have a trained Black Belt in our Quality Assurance/Quality Control staff that advises the Lean Implementation Team. This team consists of nine managers from manufacturing, four from QA and QC, and two from Engineering. Our engineers have a wealth of manufacturing experience in a broad range of industries including automotive, aerospace, and construction equipment. Several are Green Belts or have equivalent formal training.