Dolphin Sigma Solutions
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Lean Six Sigma · Manufacturing & assembly · Ontario

Find out what the line is really costing you

Twenty years in aerospace manufacturing, brought to your production floor. We get the numbers off your machines, turn them into a decision, then design and print the tooling that makes it stick.

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Certified
Lean Six Sigma Green Belt Extended by advanced Lean Enterprise certification, McGill University
Experience
20 years in aerospace manufacturing Production, assembly, risk and project delivery
Based in
Hamilton, Ontario On site across southern Ontario, remote elsewhere

Services

What we take on

Every engagement opens with a baseline and closes with the same measurement taken again. If the gain cannot be shown in your own numbers, it did not happen.

Gather

Machine data capture

Some lines have nothing to analyse, because nothing is being recorded. We fit the sensors and counters that pick up cycle times, stoppages, part counts and machine state, and bring them back to one place on your network.

Low-cost hardware at the machine, wired or wireless, on equipment far too old to have come with any of this.

  • Sensors and counters
  • Downtime capture
  • Machine state
  • Older equipment
Measure

Production data and live dashboards

Cycle times, downtime, scrap, yield, labour. We pull the numbers together and turn them into a picture people can decide from. Most floors are not short of data. They are short of one chart that settles the argument in the room.

Where a one-off report is not enough, we build the dashboard to go with it. An internal web page on your own network, showing the current state of the line to whoever needs it, on an office screen or on a display at the station. Nothing leaves your site and there is no licence to buy per person.

  • OEE
  • First-pass yield
  • Downtime Pareto
  • Control charts
  • Live web dashboards
  • Runs on your network
Improve

Process improvement

Map the value stream, find where the hours and the scrap actually go, and fix the cause rather than the symptom. Run as DMAIC, with the baseline agreed before anything changes.

  • Value stream mapping
  • DMAIC
  • Root cause
  • 5S
Flow

Assembly line design and balance

Balance the line to takt, cut the walking and the waiting, and set standard work the operators can hold. Applies to a new line and to one that has drifted.

  • Line balancing
  • Takt time
  • Standard work
  • Layout
Risk

Risk management

Find what can stop the line, fail in the field, or fail an audit before it does. Risks are ranked, owned and tracked, not listed once and filed.

  • FMEA / PFMEA
  • Risk register
  • Mitigation plans
  • Audit readiness
Deliver

Project management

Run the launch, the move or the improvement end to end: plan, budget, suppliers, trials and handover. One person accountable for the date.

  • Planning
  • Budget control
  • Suppliers
  • Handover

In-house · 3D design and printing

The fixture can be on the line this week

Most improvements stall waiting on a tooling quote. We design the fixture, gauge or assembly aid in CAD and print it ourselves in engineering-grade polymers, so the floor can try it on the real part, say what is wrong with it, and have a revised version days later instead of months.

A fixture nobody has held is still a drawing. One the operators have already argued with is a solution.

  • 3D CAD
  • Rapid iteration
  • Engineering polymers
  • Low volume

Fit

When to bring us in

How we work

Improvements that stay improved

Three rules, applied to every engagement, whatever the size.

Baseline before changes

Nothing is changed until there are numbers to change it against. That is what turns an opinion about the line into a result you can defend to a customer.

The floor helps find the cause

The people running the process help find the cause and agree the fix. A change the operators did not shape is a change that unwinds.

Everything stays with you

Standard work, training, the control plan, the tooling and the dashboards all stay with you. The dashboards run on your own servers, not ours. Nothing should depend on a consultant being on site.

Contact

Tell us what the line is doing

Send the process, the site and the problem as you see it. You get a written reply with availability and rate.

Email us
Email
bill@dolphinsigmasolutions.com
Sectors
Aerospace, manufacturing and assembly operations
Coverage
Hamilton and southern Ontario, on site or remote
Engagements
Direct, or through prime engineering and staffing partners