GMA Participates in Lean 101

Company Profile
Graphic Management Associates, Inc. (GMA) was founded in 1976 in Bethlehem, Pennsylvania. It is a mid-sized manufacturer of automated inserting equipment for the newspaper industry. GMA employs 170.

Situation
GMA attended a Lehigh Valley Manufacturers Forum (LVMF) hosted by Follett Corporation. Impressed with the results of Lean Manufacturing achieved by Follett, GMA contacted the MRC and participated in a Lean 101 seminar. 

Solution
"That got the ball rolling," says Ron Karpovich, vice president of operations. GMA executed its first Kaizen event in its pockets and grippers department. During the 5-day event, a cross-functional team was formed with individuals from different departments. Together, they identified waste and ways to improve the process. They observed, brainstormed, made drawings, and came up with a new cellular layout to improve the flow. As a result, GMA made significant inroads in reducing cycle time. 

A second Kaizen event was done in the feeder department. This brought some assemblies in-house, which helped to further reduce costs. When asked how employees felt about participating in the events, Ron says, "They were a little apprehensive at first, but as their confidence grew, they were able to implement changes."

Results
The results from the two Kaizen events were:

Testimonial
"Since the first two Kaizen events with MRC were so successful, GMA is planning to do more. Management is currently looking at the electrical and final assembly departments for possible Kaizen events."

Ron Karpovich
Vice President of Operations