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Copyright 2004
Modern Group, Inc.
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Continuous improvement demands require all manufacturers to take a serious, structured approach to value analysis and the adoption of lean process methodology while at the same time allowing latitude for creative breakthroughs.

In line with this expectation, Modern Forge Companies strive to identify opportunities for continuous improvement and cost reduction to be passed directly to the customer, while increasing the value of the entire business relationship. Examples of these processes are:

1. Lean Manufacturing
   • Commitment to 5S
   • Adoption of TPM
   • Process mapping to drive out non-value
2. Defined Engineering Process
   • Advanced Quality Planning
   • Forging Envelope and Machine Datum Analysis
   • Review FEMDA customer
   • New Job Process Meeting
   • Prepare Process FMEA
3. Scheduled job review to address Opportunities for Cost Reduction
   • Gross weight reduction
   • Tool design to expand die life
   • Process upgrade (increase pieces/platter/productivity)
   • Set up reduction
   • Scrap/rework
4. Long-term contracts with steel mills to maintain or reduce material expenses, material with integration of low cost offshore.
5. Thermal treatment/material selection to avoid excessive Q&T costs.
6. Provide integrated forge and finish process to reduce waste and minimize administrative expense.
7. Eliminate typical shot peen cost through proprietary in-house shot blast process.

Modern Forge Companies has been able to "inflation proof" our price structure to most customers. In addition, Modern has extended in excess of $600,000 in annual cost reductions to our customers over the last two years through continuous improvement exercises.

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