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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.
Tampa, FL - Working with the project managers at the Florida Manufacturing Extension Partnership (MEP) has proven both profitable and worthwhile, according to Scott Feldman, general manager of Kaf-flex, a manufacturer of hoses for swimming pools and hot tubs.
"I turned to the Florida MEP because I wanted to get an outsiders view on the company, our production lines and our manufacturing processes," said Feldman. "Since Kaf-flex was only recently purchased by Heyco Products Co. of New Jersey, there was a willingness to get input from outside consultants."
"I was definitely open to suggestions," Feldman added, "but I must admit, the results were more successful than I initially thought they ever could be."
"I decided the best way to solve our problems, including some structural issues within the company, was to get involved in the Time Wise Principles of Lean Manufacturing facilitated by the Florida MEP," Feldman said.
In a nutshell, within a few weeks, several deficiencies had been identified and addressed and a significant improvement had been made in the waste and scrap generated by the Kaf-flex manufacturing process.
MEP’s project managers discovered that a major contributor to waste was a lack of awareness of the total cost of wasted materials, including lost production opportunity and handling of the product that is systematically destroyed when not meeting specifications.
"We make PVC hoses through an extruding process," Feldman said. "The hoses are made in 100-foot lengths. Unfortunately, if something is wrong with a portion of that hose, the entire thing becomes scrap."
With 11 manufacturing lines going 24 hours a day, seven days a week, plenty of hose is being made by Kaf-flex. "The problem is simple, however," Feldman said. "When we make hose that fast, we need to monitor and understand our process so well that we make necessary adjustments before any scrap is made."
With MEP’s help, there is now a system in place to improve the set-up, monitor the hose manufacturing and a way to measure how much scrap has been made and have it categorized into certain categories.
Feldman said, "Scrap material generation has been reduced by an equivalent of several thousands of dollars per year. In addition, thanks to the Lean Manufacturing, we expect to experience a considerable amount of savings in labor costs."
A 12-year old company, Kaf-flex is located in a 36,000-square-foot facility and currently has 30 employees. Kaf-flex specializes in flexible PVC hose and electrical conduit that is produced using state-of-the-art laser monitoring devices that help to ensure consistent high quality products. As one of the premier suppliers of hose, conduit and tubing, Kaf-flex also offers custom cutting, printing and packaging of products to meet the wide variety of individual customer needs.
At the present time, the company sells most of its products to OEM manufacturers and through wholesale distributors around North America. A second plant was recently purchased and is now open in California.
"We are continuing to make improvements based on the specific recommendations we received from the project managers and the Lean Manufacturing process definitely will continue," said Feldman.
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.