Value Stream Mapping and Kaizen Events

• Reduced set-up time in the coil slitting area by 14 percent per line.
• Reduced walking time on one line by 22 percent and on the other by 13 percent.
• Reduced order processing time from 6.5 days to one day.
• Established documented procedures and roles to make these improvements standard practice.

"We will be implementing the changes recommended by the Manufacturers Resource Center and are looking forward to our improved ability to add to our already excellent customer service by shortening lead times, improving the customer's ability to get information in a timely fashion, and in maintaining our cost-competitiveness."

- Remco Blaauw, President

Lean 101 and Value Stream Mapping of Pilot Product Line

• Reduced lead times on the pilot product line by over 50 percent.
• Reduced lead times for the quoting process by 50 percent.

"The Manufacturers Resource Center is trying to help manufacturers in the industry save jobs and keep industry and jobs in the area. Technologically, they give companies the assets they need to stay in business and pursue other avenues."

- Ray Harries, President

Set-up Reduction

• Set-up / changeover times on the Hayssen machine were reduced by 66 percent which allowed 300,000 additional packages per year to be filled in the same amount of time.

"MRC has been instrumental in applying lean techniques to improve our set-up process and increase our output which really has had a positive impact on our bottom line."

- Marianne Brown Egolf, Director of Operations

Value Stream Mapping

• Reduced work-in-process inventory by 80 percent.
• Increased on-time delivery from 65 to 95 percent.
• Reduced lead times from six weeks to six days.
• Dramatically reduced overtime and improved financial results.
• Improved product quality.

"Overall, we are an excellent example of what positive results can happen when lean manufacturing techniques are properly applied utilizing the expertise available at the Manufacturers Resource Center."

- Greg Wolf, President

Lean 101, Value Stream Mapping, Kaizen Event and Implementations

• Scrap rate went from 8% of sales to under 2% of sales.
• Order processing time from administration to production on the floor was reduced by 30%.

"Saint-Gobain Sully has worked with MRC on many projects. Due to the MRC's familiarity with our organization coupled with their extensive lean manufacturing knowledge and industry experience and the outgoing personality of their staff, they have energized our firm to successfully implement the techniques with a noticeable contribution to our bottom line. MRC has been instrumental in shaping our continued success."

- Brian Furchner, Manager of Technical Services

Lean 101 and Value Stream Mapping

• As a result of the Lean training, Kaizen event, and Value Stream Mapping, management and operations were able to come to a unanimous solution. They designated specific tools for each machine, and each crew now records their work in a log book. They note how the machine ran, any problems they had with it, and the log acts as a reference for any recurring problems. Chris says they saw an immediate reduction in set-up time, and procedures are now more uniform.

Shalmet has benefited from its working relationship with MRC for several years. "We knew from past training experience with MRC that they would be able to get the job done quickly and effectively," says Steve. Shalmet currently has plans to do more training with MRC.

- Steve Gombar, Human Resources Director