Lean Transformation: Creating more value from the core
The Problem
Bob Hawk, Entrematic Plant Manager, had a vision to transform his plant operations by dedicating to and strategically implementing Lean based models. The company had previously implemented Lean concepts in certain areas; they documented some projects but failed to standardize the changes. As they began making progress, they soon realized that much more was needed to achieve a true Lean transformation. Mr. Hawk was determined to convert his vision into reality and understood that Entermatic needed to become efficient with the project implementation and standardization phases thus turning to TMAC for support.
The Solution
The decision was made to begin their journey first through Lean Leadership Transformation. The plant manager, along with his leadership team, began the training and established priorities by identifying areas of opportunity through a companywide Value Stream Map. The leadership team would also rotate heading projects but were all still involved in some way. By doing this, they understood that the involvement of every department (Quality, Materials, Operations, Engineering and Production) was the key to their transformation. As they continued with their companywide initiative, 5S, VSM (Value Stream Mapping), SMED (Single Minute Exchange of Die), and TPM (Total Productive Maintenance) became part of their everyday vocabulary.
The Results
As a result of Mr. Hawk’s vision, approximately $200,000 in cost avoidance, risk reduction and cost reduction ensued from the implementation of just three projects. Overall, they were also able to achieve quality improvements, waste reductions and standardizations. 200+ employees received Lean training and after several months, Entrematics’ culture has transformed into a Lean environment. The employees have adapted and embraced the changes; most have ideas of their own for improvements and are excited for the future of their company.
Profile
Customer
Entrematic
County:
Hidalgo
Industry
Engineering Services
NAICS:
541330
TMAC Services:
Lean Transformation
Who to contact:
David Ortiz
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