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Time Wise® Success Stories
The following is a Lean Case Study from our MEP MSI-managed family of Manufacturing Extension Partnerships (MEPs) that demonstrates the impact of the Time Wise® Management Systems’ Lean transformation methodology deployed through Time Wise® Solutions training products.
John Matouk and Company increases productivity and cuts man-hours while creating fashionable, state-of-the art facility
Fall River, MA - John Matouk and Company has been making some of the world’s most luxurious linens for more than 70 years. Now a third generation business, the family remains committed to John Matouk’s vision of designing and manufacturing fine quality products, maintaining its position as an industry leader in a facility that is as fun as it is functional.
Recently, the company moved their main manufacturing and distribution operation to a new facility in Fall River, Massachusetts and George Matouk Jr., the current President and CEO, wanted to use the move as an opportunity to set up the new plant to function in the most efficient way possible. After obtaining an Industrial Development Bond through Mass Development, The Associated Industries of Massachusetts (AIM) referred him to the Massachusetts Manufacturing Extension Partnership (MassMEP) for assistance with the plant layout.
"We wanted to focus on making the necessary changes to avoid bottlenecks during production and improve on-time delivery to customers," said Matouk. "At the same time, we wanted an optimal production environment that was as spacious and bright as it was functional."
After completing the Lean Manufacturing training, the group then began a Time Wise Value Stream Management System session, which maps the existing factory’s product and process flow and helps a company determine a more efficient layout. The Company was able to store large rolls of fabric in the new facility, as opposed to a separate off site warehouse, making the raw materials accessible to everyone. Now there’s even room for expansion, if needed in the future.
The task of developing the new factory layout was driven by a process known as Systematic Layout Planning, which is a systematic, data driven detailed process that is focused on developing the most effective and efficient facility layout possible. The project involved a team of Matouk employees working with MassMEP over a period of weeks to develop a new detailed facility layout.
The company also purchased special air cushioned tables to make stacked fabric easier to move, and easier to cut. The bar coded work orders are scanned periodically so that the orders can be located at any time. The new programmable embroidery machine can embroider several pieces at one time, freeing up employees to do more intricate and custom work. The completed linens are then stored in the opposite end of the warehouse from where the fabric is kept. The new layout allows work to travel in a circle, reducing the distance work in progress travels, resulting in a 10 percent increase in productivity while cutting man-hours per week by the same amount.
When the plant layout was complete, architects needed to do some fine-tuning, and the MassMEP left them with the tools needed to produce some remarkable results. The walls are painted in pastel tones, the lighting is bright, and the environment is comfortable. The employees even have new colorful, stylish furnishings in the lunchroom.
"The new environment seems to have been inspirational," adds Matouk. "Morale is high, the surroundings are pleasant, and the employees really feel they had a voice in the way the new facility was laid out. The MassMEP has really enabled us to build a production department environment that was truly optimal for the product line. They brought forward a level of expertise to assist us in dealing with our specific problems that we never would have been able to afford or find otherwise."
The Lean success story you have just read is an actual case study from one of our MEP MSI-managed state MEP centers. Our affiliate MEPs utilize the Time Wise® Management Systems’ Lean transformation methodology based on world class Time Wise® Solutions training products. MSI-managed MEP center project managers are vetted and trained at the Time Wise® Institute and receive access to a full suite of integrated Time Wise® products.
Our certified Lean-trained project implementation facilitators work with a company's management team to identify conditions that impede the ability to become more competitive and prosperous. During intensive hands-on training sessions with employees at all levels of the organization, our certified Time Wise® MEP specialists solve specific problems from the shop floor to the front office and assess how well each department contributes to overall productivity and profitability. Essential tools are furnished to optimize performance and provide guidance so that companies can use those tools and systems effectively on their own to sustain the improvement process.
Since our MEP affiliates have begun utilizing the Time Wise® Solutions suite of products, their performance has increased significantly. Just a fraction of the accomplishments of our affiliate state MEP centers have been reported on our web site. Click here to read additional success stories.
To learn more about Time Wise® Solutions products or to join the Time Wise® Management Systems team of MEP Centers, please call 1-866-USA-MADE (1-866-872-6233) or email us at: info@timewisems.com.
Our certified Lean-trained project implementation facilitators work with a company's management team to identify conditions that impede the ability to become more competitive and prosperous. During intensive hands-on training sessions with employees at all levels of the organization, our certified Time Wise® MEP specialists solve specific problems from the shop floor to the front office and assess how well each department contributes to overall productivity and profitability. Essential tools are furnished to optimize performance and provide guidance so that companies can use those tools and systems effectively on their own to sustain the improvement process.
Since our MEP affiliates have begun utilizing the Time Wise® Solutions suite of products, their performance has increased significantly. Just a fraction of the accomplishments of our affiliate state MEP centers have been reported on our web site. Click here to read additional success stories.
To learn more about Time Wise® Solutions products or to join the Time Wise® Management Systems team of MEP Centers, please call 1-866-USA-MADE (1-866-872-6233) or email us at: info@timewisems.com.