The following field project study was performed at a sheet metal manufacturer of
operator cabs, roll-over protective structures (ROPS), and electronic enclosures and consoles.
This study describes literature, setting up a manufacturing line, implementing four modern day
press brakes, and implementing the press operator and water strider standard work during the full
production phase. The modern day press brakes possess the latest in bending technology and
were a necessity in order to support Company XYZ’s strategic initiatives related to growth and
continuous improvement. The press brake project was justified and approved because Company
XYZ’s metal fabrication processes are more than 30 years old when compared to other leading
businesses. The intention of this study was to verify a successful installation of four new modern
day press brakes. The field problem resulted in several positive outcomes. These outcomes
were a 36% improvement in the average forming efficiency, a 75% reduction in scrap, a onetime
reduction in inventory, and a consolidation and reduction in maintenance costs by 15%. The
verification methods included: a statistical process control chart, a reduction of inventory from
five days to three days, scrap reduction, and an improvement of operator labor efficiency and
delivery performance.