(616) 866-4479

©2019 by Byrne Tool + Design.

Lean Manufacturing

Also known as Common Sense Manufacturing, or CSM, Lean Manufacturing is a unique initiative for driving out waste. Using a blitz approach, Byrne conducts eight CSM events annually during which we go narrow and deep to build incremental improvements throughout the company. This CSM process includes review and action in the following areas: Sort, Shine, Straighten, Standardize and Sustain. We tend to focus the majority of our events on the non-value portion of mold building, because it makes up about 70% of manufacturing lead time. In 2006, we were able to reduce our lead time for an average mold build from eight weeks down to six weeks – a full 25% reduction in lead time. Below is a brief walk through of a recent 5S event.

Organizations and Accreditations

AMBA

American Mold Builders Association member

RACC

Rockford Chamber of Commerce member

MTG

Michigan Tooling Group Member

AMBA

American Mold Builders Association member

RACC

Rockford Chamber of Commerce member

MTG

Michigan Tooling Group Member

ISM

Institute for Supply Chain Management member

ISO 9001-2000 Certified

Registered through Intertek/Entella

Our Staff

Dan Hosford

General Manager

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Andy Baker

Title

A solid project manager and sales representative rolled into one, Andy's technical experience and attention to detail make him a great asset in solving difficult customer problems. His love of the outdoors and interest in hunting provide additional opportunities for Andy to hone those same meticulous technical skills outside of the office.

Doug Bylsma

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For over 20 years, Doug has been running EDM machines at Byrne and his dedication to our organization led him to also cross train in CAM programming and design. Doug's commitment to any task, as well as his love of fabrication, is reflected in every aspect of his life. He recently put those skills to the test by completely restoring his own truck after it was badly damaged in an accident.

Doug Gamm

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As manager of the graphite department, Doug leads our production of high quality electrodes for the EDM process. In his off hours, he enjoys making and flying model planes and is currently pursuing his pilot's license.

Duane Rozema

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After 40+ years of working in the trade, experience is Duane's heritage and his legacy. Early in his career, Duane worked with his father for a number of years at Quality Die and Mold, and later brought his considerable expertise and talents to Byrne.

Jackie Overley

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Always driven to get the best product and service available, Jackie manages all of our office and purchasing activities. An active volunteer for education and awareness, Jackie commits much of her spare time to support a variety of causes in the community.

Jeremy

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As one of our lead mold makers, Jeremy understands the level of commitment needed to serve the customer. That same dedication to quality and success drive his personal passion for archery, as his many trophies demonstrate.

Jim Sutherlin

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Jim was our first journeyman mold maker and CNC programmer operator, joining our team back in 1984. Since that time, Jim has helped develop our capabilities in these areas, mentoring many of his coworkers along the way. A dedicated single father, Jim enjoys playing golf, and a variety of other sports, in addition to raising his twin daughters.