Analog Devices, Inc. Boosts Productivity to Double-Digit Highs Through Continuous Training

Company Profile

Founded in 1965, Analog Devices, Inc. specializes in solving the engineering challenges associated with signal processing in electronic equipment. Headquartered in Wilmington, MA, Analog Devices, Inc. is a world leader in the design, manufacture, and marketing of a broad portfolio of high-performance analog, mixed-signal, and digital signal processing (DSP) integrated circuits (ICs) used in virtually all types of electronic equipment by over 100,000 customers worldwide. These signal processing products play a fundamental role in converting, conditioning, and processing real-world phenomena such as temperature, pressure, sound, light, speed, and motion into electrical signals to be used in a wide array of electronic devices. 

Situation

Analog Devices, Inc.'s Camas, WA manufacturing site has maintained a long-standing relationship with Impact Washington that dates back before its name change from Linear Technologies. The Camas site's initial engagement with Impact Washington in 2011 included LECP Bronze Certification and Lean training for the core production team and the management and supervision team. After eight years of training, which included Kaizen events, Training Within Industry (TWI), and LECP training, Analog Devices, Inc. continued to incorporate more complex processes than ever before in an on-going attempt to improve cycle time and yield of the product. Despite this, the company continued to experience some unpredictable results and sought more stability in those areas. The management team recognized that they could ultimately reduce wasted energy and time by training all of their employees.

Solution

Analog Devices, Inc. reengaged with the Impact Washington team in 2018 for on-site training of all employees in Toyota Kata to provide a consistent way for the entire company to think and approach work issues. Kicking off with a two-day on-site training class, the consultant then returned for a follow-up 15-day session. Impact Washington provided a consultant to train employees of all shifts (day, night, midnight). Incorporating a "coaching aspect" to the contract helped educate employees and build confidence in using the tools while implementing a more standard approach to all processes. Since completing their training, the company has been rolling out the Kata approach as a continuous improvement method for all internal projects, regardless of size. Everyone now enlists the same terms and languages to address identified issues and recommended solutions. Because they recognized the value of their investment, Analog Devices, Inc. has since requested four more coaching and training sessions, regardless of whether or not a JSP grant can be obtained.

Results

• Management has responded positively to training. As a result, the corporate office is pushing Shingo guiding principles, which helps employees meet the goals identified by management.
• The Kaizen events resulted in the development of a Kanban scheduling system implemented throughout the entire factory.
• Increased productivity by 25-30% and doubled line speed (over the 8 years of continuous training).  
• Creation of Lean champions among employees, which provides more widespread knowledge to start applying throughout the company.
• In the last year, Analog Devices, Inc. has applied the Toyota Kata method to 55 new internal projects on the production floor alone. 
• Impact Washington submitted Analog Devices, Inc. into the Seattle Business Magazine 2019 Manufacturer of the Year award show.
• Increased employee empowerment and engagement to not just identify problems but also provide solutions. The most significant impact has been with the off-shift employees, who are now more excited and feel empowered by being recognized for their problem-solving.