Plant Tour Series: Ophir Optics DVD

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Item #: 70V1046

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Ophir Optics LLC designs and manufactures infra-red optics and lens assemblies for the defense, security and commercial markets. Ophir employes just 88 employees in its 40,000 square foot facility located in N. Andover Massachusetts. Ophir started its lean journey in 2008. In the years that followed, employees participated in "learn-and-do" training classes in Standardized Work, Set Up Reduction, 5S, TPM, Six Sigma, Cell Manufacturing & Pull Systems/Kanban. The payback for giving their people the time to learn and practice lean and six sigma concepts has proved well worth the effort.

Ophir credits its results to employee project work and suggestions. These include:

  • 70% reduction in manufacturing lead time,
  • 20% reduction in total inventory,
  • More than $1,000,000 in efficiency improvements (labor and equipment costs),
  • 23% reduction in fabrication area footprint while achieving a 30-40% output quantity increase per year,
  • New business opportunities generated by reduced costs achieved as a result of new coatings developed using 6 Sigma methods,
  • > $100,000 in scrap reduction projects using 6 Sigma methods,
  • And significant reductions in hazardous waste and recognition by the state of MA as a 2011 champion in toxics use reduction.


However, Ophir cites one benefit above all as a result of its lean and six sigma training: its ability to develop and promote its employees. Lean training at Ophir facilitated promotions from within for manufacturing leadership positions. In fact, 16% of its Direct Labor people were promoted into leadership positions in 2011 alone.

The newest installment in the GBMP Virtual Plant Tour series showcases the remarkable strides a company can make when it is committed to continuous improvement and involves employees every step of the way. Ophir truly understands that it is the employee who creates and delivers value to your customers. And your team will too afeter seeing this video!

Published by: Greater Boston Manufacturing Partnership

Item# 70V1046

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