Issue link: https://iconnect007.uberflip.com/i/1538999
SEPTEMBER 2025 I SMT007 MAGAZINE 47 real-time data-driven decision making, this created a manufacturing environment that was both flex- ible and efficient. One of our PCBA process and quality engineers stated, "For our HMLV operation, this tailored Lean approach has been nothing short of transforma- tional. We finally have flow that works with our reality, not against it." The Impact: Measurable Excellence in Manufacturing Performance The implementation of Lean Excellence for HMLV Manufacturing delivered measurable, sustained improvements across all critical performance areas. Most significantly, average lead times dropped from 107 days to 37.1 days—a 65% reduc- tion that directly translated to improved customer satisfaction and competitive advantage. Quality improvements were equally impressive, with rework hours falling from 6% to 4%—a 33% reduction that freed up valuable capacity and reduced costs. More significantly, the operation achieved zero field failures reported due to downhole PCBA manufacturing defects. This achievement was particularly meaningful in the high-reliability electronics sector, where a single failure thousands of feet underground can result in costly downhole operations and significant customer impact. Perhaps most importantly, operational efficien- cies are rebounding with nearly 10% year-over- year improvement from 2023 to 2024, despite maintaining the expanded workforce capability. This demonstrated that the improvements were sustainable and scalable, not temporary gains that would disappear under pressure. The transformation was achieved over a three- year period from 2022 to 2025, proving that significant HMLV improvements are possible with the right approach and sustained commitment. While academic research shows that successful Lean transformations in HMLV environments remain "notable and not (yet) typical across HMLV manufacturing,"4 our results demonstrate the high impact achievable when Lean principles are properly adapted to HMLV realities. The real-time data systems implemented as part of the methodology continue to drive ongoing improvements, creating a foundation for continu- ous enhancement that adapts automatically to changing product mixes and operational demands. With manufacturing excellence built on skill- based flow and a proven methodology designed specifically for HMLV reality, the operation now