Posted by William Mullane | November 7, 2016
Transtector Systems, a privately-owned manufacturer in Hayden Lake, Idaho, has designed and built high-end surge suppression systems since 1971. The company has grown to over 125 employees and has been experiencing a period of high growth in its primary product. The resulting quality and delivery challenges were only being met through a substantial amount of overtime and extra effort. The company’s management team was looking for ways to improve its operations.
After attending a TechHelp workshop on Lean Manufacturing, the company asked the local TechHelp Manufacturing Specialist to do an assessment of its operations. Transtector’s management team subsequently undertook a Value Stream Mapping project with TechHelp’s assistance. Current operations were reviewed, a new manufacturing cell to streamline operations was envisioned, and an action plan was developed and implemented.
The new product cell has led to substantial improvements throughout
- Lead time for typical orders is down from three weeks to three days
- Inventory levels have been reduced by 60%
- Travel distance and floor space have been reduced by 75%
- Over $100,000 will be saved in direct labor expenses
- Initial results indicate an immediate productivity gain of over 20% has been