1 of 8

Cascade DAFO Value Stream

Olivia Girard, Jenny Park, Luke Triemstra, Matthieu Cazajus, Gabrielle Hilgart

2 of 8

About The Company

Location: Ferndale, Washington

Employees: 178 full-time and part-time

Products: World Leader in Custom Dynamic Orthotics and Fast Fit Orthotics

​

​

Helping Kids Lead Healthier, Happier Lives.®

“We believe better mobility gives children a wider range of experiences, more success in their activities, and ultimately more control over their lives.”

​

3 of 8

Product Characteristics

Custom dynamic ankle foot orthosis (DAFO):

Features:

  • Tailored fit
  • Adjustable DAFO length
    • To the knee/To the ankle/In between
  • Left foot only/Right foot only/Both feet
  • Personalized coloring options
    • Straps, foam padding, and brace

Takes longer than the Fast Fit models

Does not include:

  • Thumb Things, Knee ankle foot orthosis (KAFO), and Knee braces.

4 of 8

Value Stream Map

5 of 8

Lean Implementations

Labeling bins

Maintain Stations

Toaster Ovens/Crock Pots

Green Lean

Line of Sight

6 of 8

Recommendations

​

​

  1. Plaster Process: Improve ergonomics and eliminate batch processing
  2. Quality vs Quantity: Work-station monitors
  3. Labeling system for image transfer
  4. Plastic pulling process

​

7 of 8

Conclusion

Cascade DAFO is on a journey to lean.

Culture of continuous improvement.

Many opportunities for improvement on the shop floor to improve the cycle times and improve the working environment for employees.

​

8 of 8

Acknowledgements

Professor Peter Haug�Ryan Evans