Success Stories

Founded in 1999, Time Wise has grown to become one of the most recognized lean manufacturing service provides in the United States. But our suite of performance improvement products extends far beyond their origins in both breadth and depth. They encompass a wide spectrum of best-practice methodologies that capture the experience of hundreds of seasoned practitioners across multiple industries, thereby ensuring the best possible implementation path.

Time Wise® Solutions consists of a fully integrated suite of Lean Enterprise, Quality Management Systems and Business Continuity Planning tools that organizations can combine in different ways to accommodate their requirements. The flexibility of these tools enables us to refine an initiative to meet industry-specific requirements.

Time Wise tools are used by almost one-third of the all Manufacturing Extension Partnership (MEP) centers, five of the top seven defense prime contractors, U.S. Navy shipyards, U.S. Naval Warfare Centers, U.S. Navy SUBMEPP, U.S. Air Force facilities, the Office of Naval Research and Missile Defense Agency-funded supply chain programs, consultancies and educational institutions.

Utilizing the Time Wise suite of products, our national sales team and affiliated MEP centers have served thousands of manufacturers, stretching from Hawaii to Maine and from Alaska to Florida. In the last six years, we’ve helped those manufacturers create or preserve more than 14,000 jobs.

But we’ve also developed products and services that extend far beyond the manufacturing floor. Our product development team has applied the principles and methodologies of Lean Enterprise and adapted them to apply to offices, government agencies, workforce investment systems, hospitals and healthcare providers. Improved service, greater efficiency, less waste, lower cost – these are goals for which every business and organization strives.

The following is a composite of Testimonials from our TWMS-managed family of Manufacturing Extension Partnerships (MEPs) that demonstrates the impact of the Time Wise® Management Systems’ range of services that integrates workforce organizations with economic development, and provides workforce investment systems with new opportunities for meeting local labor and business needs. For more information on how we can help your organization, contact us.

Innovation Program

Ridgetop Group, Inc.

Tucson-based Ridgetop Group, Inc., an engineering, research and development company, specializes in electronic prognostics technology for critical systems. Their built-in self-tests estimate the remaining useful life of components so that they can be replaced or repaired before they malfunction. For their work with military applications, this is crucial as Ridgetop develops the technology for warning devices that alert fighter pilots of potential equipment failures.

Ridgetop knew their technology could be useful in other avenues, but were not sure how to proceed. A project team from Time Wise and the Arizona MEP was brought in to assist the company in developing a strategic business plan and help with marketing and commercialization. Through this initiative, Ridgetop was able to determine the automotive industry was the most viable commercial sector for them to transition to.

“Our technology has a number of safety applications for cars, like predicting degradation of anti-lock breaking systems and electronically alerting the driver or their mechanic of a potential problem,” said Doug Goodman, president and CEO of Ridgetop Group, Inc. “Thanks to the project team, we are now working with a major auto manufacturer on ways to implement our technology into their vehicles. MORE

Intelligent Micro Patterning, LLC

Intelligent Micro Patterning, LLC (IMP), develops and produces imaging equipment for creating substrates used in micro-, meso-, and nano-technology devices. Since 2001, IMP has endeavored to become a leader in innovative imaging heads. Although IMP’s systems have enjoyed success with users, these users were ultimately responsible for setting up the process runs themselves. In an effort to assist its busy customers, IMP decided to implement a ‘semi-automatic’ method for enhancing the existing system through the implementation of significant process characterization and extensive processing runs.

To better serve users, IMP used a project team from Time Wise and the Florida MEP to provide an evaluation of IMP’s products and procedures. Through this collaboration and consultation, IMP found new ways to apply its processes to untapped market areas such as biotechnology and 3D device fabrication. The project greatly enhanced the company’s offerings to its customer base, enabling it to complete its first sale to Asia and creating new jobs, stated Jay Sasserath, CEO of Intelligent Micro Patterning. “This work has allowed IMP to grow our revenue, profitability, and find new uses for our base technology.” MORE

TurboCombustor Technology

TurboCombustor Technology, Inc. (TCT), founded in 1965, manufactures complex sheet metal fabrications for turbine jet engines in the aerospace and industrial markets throughout the world. Looking to increase its manufacturing capacity while reducing defects and improving delivery, TCT contracted for a training project involving lean production and advanced production technologies.

The Innovation Program training sessions led to a breakthrough that introduced new approaches to laser assisted drilling and titanium alloy material processing, as well as how to change the flow for components produced for two key customers, created primarily within the same work cell. As a result of the project, TCT reduced floor area required for key production by 33 percent, maintained employee and physical resource levels, simplified production flow using visual lean and reinforced ERP, reduced defects by 50 percent through inventory and WIP reduction, achieved on-time delivery and eliminated the need for overnight shipments. MORE

Applied Thermal Sciences

Applied Thermal Sciences, Inc. (ATS) is primarily a research and development lab that does classified work for the U.S. Navy and Department of Defense. But when ATS developed a new laser welding process that had significant possibilities for commercial use in many industries, the company recognized it needed assistance in order to further develop and market the new technology.

ATS engaged Time Wise Management Systems (TWMS) and Maine MEP to assist the company with the commercialization process. The project team implemented a strategic and technical roadmapping assessment that identified the strengths and opportunities for a new company. The team also looked at workforce development strategy and how the company could take its invention to the next level – commercialization. Market surveys demonstrated the potential for the new laser welding machine, especially in the transportation sector with rail cars, truck beds and tractor trailers.

As a result, ATS has partnered with Esab, the largest welding company in the world, licensing them with its technology to sell the laser welding machines worldwide. MORE

Ducommun Technologies (DTI)

Phoenix-based Ducommun Technologies, Inc. (DTI) is the country’s second largest supplier of electromechanical illuminated push button switches for the aerospace industry. It also is a major supplier of microwave switches and components used for the wireless communications. A third tier supplier in the aerospace industry, DTI sought to improve its production efficiency in order to meet the growing demands of its clients.

Beginning with a technology road that was followed by Lean training and simulations, the project team recommended a series of changes that were adopted with great success. Hours per assemble for a radar rack produced for Boeing were dramatically reduced by 34 percent, enabling the company to achieve a significant cost reduction. MORE

Research Integrations, Inc.

Research Integrations, Inc. (RII) has been developing and applying design principles to enhance human performance in simple and complex task environments. The Tempe, Arizona-based company assists customers nationwide including the FAA, NASA, Boeing Commercial Airplanes, Booz Allen Hamilton and other research and industrial organizations in the aviation, automotive and manufacturing sectors.

The company recently underwent a major transition, going from a solely service-based business model to a product-based, service-differentiated model with the launch of a new software tool. To assist with this business transformation, RII brought in a project team from Time Wise Management Systems and the Arizona MEP. The team conducted an assessment that identified specific objectives and recommendations that enabled RII to achieve its product development goals. MORE

Globe Composite Solutions, Ltd.

After four years of testing, the U.S. Postal Service (USPS) selected Globe Composite Solutions, Ltd. (GCS) to produce the product to replace its aging metallic-based sorter systems throughout the entire bulk mail center distribution network. Recognizing that the contract would strain their extremely labor-intensive production process, GCS engaged Time Wise Management Systems (TWMS) and Massachusetts Manufacturing Extension Partnership (MassMEP) to conduct an enterprise-wide assessment of their business. This process benchmarked the company’s business practices, production processes and technology core competencies. The Innovation Program project team consequently developed a technology roadmap and professional workforce development plan for the organization.

GCS then embarked on a project to train the entire workforce on general Time Wise lean principles. An intense review of the work flow, facility layout, inventory control processes, equipment utilization and production scheduling tasks was conducted.

The implementation of Time Wise lean trainings resulted in significant improvements:
     •  Reduction in travel distance for carriage assembly and personnel by more than 98 percent;
     •  Reduction in carriage assembly area by more than 95 percent; and
     •  Reduction in the space occupied by the entire USPS product line by more than 85 percent.

The implementation of “quality at the source” increased first pass yield to more than 99 percent. As a result, GCS has been able to meet demanding production schedules set by the USPS as productivity was increased more than 60 percent using the same staffing. MORE

Universal Forest Products

Universal Forest Products (UFP) has become a major supplier to several markets and is the largest manufacturer of engineered roof systems and a leading producer of pressure treated lumber nation wide. Given the size of UFP operations, it is not surprising that UFP is also the largest customer of North America’s mills. The strategic planners in its Chandler, Arizona facility decided to improve their corporate philosophy to make improvements in the way they operated the business. The main objective of improvement was customer focused, with an emphasis on improving on-time delivery to all customers.

To accomplish this strategy, UFP partnered with Time Wise Management Systems (TWMS) and the Arizona Manufacturing Extension Partnership (Arizona MEP) to implement a lean assessment. As a result of the assessment, UFP was awarded an H-1B grant, funded by the US Department of Labor and administered by Northern Arizona Council of Governments to assist with training expenses. Since most of the production team is non-English speaking, the project team implemented the use of videotaping to film the processes the team wanted to improve. Videotaping helped illustrate the benefits of maintaining changes and improvements made during various phases of Lean and helped transcend the language barrier. Following this breakthrough, the Arizona MEP team was able to design a Lean implementation program that gave UFP Phoenix the tools they needed and skills to use the tools. MORE

Thos. Moser Cabinetmakers

Thos. Moser Cabinetmakers, a trusted producer of fine handcrafted wooden furniture, has boomed into a business with 190 employees, including over 95 craftspeople, and spans six showrooms around the country. With the company expanding, Colleen McCracken, CFO, along with the senior management team wanted to ensure they kept competitive in the industry without compromising the craft.

“We were at a good time to explore Lean, and wanted to do it the right way. So we called on the Maine MEP, who would perform a business assessment for us,” said McCracken. “We knew this would be an encompassing commitment, but we really wanted to make Lean part of our corporate culture and a way of life for us at Thos. Moser.” MORE

Katahdin Forest Products, Inc.

A leading supplier of cedar log homes and manufactured cedar products, Katahdin Forest Products, Inc. provides high quality, custom cedar log homes to the high end of the custom home market. The company differentiates itself by manufacturing homes in a way that dramatically shortens the time from order to ownership – thus reducing over all acquisition costs.

Recently, thanks to ABC’s “Extreme Home Makeover” show, Katahdin Forest Products, Inc. had to interact with several of its dealers in a whole new way. The company was selected by ABC to build a log home for a family in southern Maine. However, the opportunity also posed extraordinary risks of failure if Katahdin did not plan and invest wisely to meet its anticipated growth.

In an attempt to maximize its growth potential while minimizing its risk, Katahdin worked with Time Wise Management System (TWMS) and the Maine Manufacturing Extension Partnership (Maine MEP). With the assistance of a US Department of Labor High Skills Training Grant, administered by the Coastal Counties Workforce Board, the project team implemented a strategic business and technology assessment. The assessment identified that Katahdin held a strong competitive technology advantage over other companies and that its dealers experienced shorter sales cycles, quicker commissions on closed deals and reduced risk of failed projects. MORE

Jøtul North America

Jøtul North America (Jøtul) is one of the largest manufacturers of cast-iron wood and gas stoves, inserts and fireplaces in the world today, but that doesn’t mean there isn’t always room for improvement. Jøtul’s worldwide reputation for quality workmanship has certainly made the Portland, Maine-based facility a huge success.

The company emphasizes changes to the process that will reduce the needed production area space and warehouse storage space while utilizing standardized production processes, reducing handling of production components and increase flexibility in meeting customer demands.

Recognizing the need to be open to new ideas and techniques that will ensure the company’s continued success in the future, Jøtul engaged Time Wise Management Systems (TWMS) and Maine Manufacturing Extension Partnership (Maine MEP). With the assistance of a US Department of Labor High Skills Training Grant, administered through Coastal Counties Workforce Board, Jøtul and the project team implemented a lean program centered on education and training projects that led to continuous improvement methods through out the production area. MORE

CHIPCO International

CHIPCO International’s officials recently decided to lay the company’s cards on the table and aggressively seek to expand its share of the international gaming industry by producing a better poker chip.

The company engaged Time Wise Management Systems (TWMS) and Maine Manufacturing Extension Partnership (Maine MEP) to help them identify the resources needed to succeed. With the assistance of an H-1B High Skills Technical Training Grant funded by the US Department of Labor and administered by Coastal Counties Workforce Board, the project team performed a strategic business and technology assessment of the company. The assessment determined that CHIPCO held a strong competitive technology advantage capable of reversing the market share with its main competitor. MORE

Innovative Mold Solutions, Inc.

Innovative Mold Solutions, Inc. (IMS) specializes in the development and operation of technologically advanced high performance injection molding systems that are engineered to provide the absolute lowest manufacturing cost platform. By employing highly skilled workers, including almost a dozen engineers, IMS was able to produce lower cost, higher quality products than its competition. But IMS faced a problem of how to relay the significant cost and quality differences between the company and its competition.

With the assistance of Time Wise Management Systems (TWMS) and Massachusetts Manufacturing Extension Partnership (MassMEP), combined with a US Department of Labor High Skills Training Grant administered by the Central Massachusetts Regional Employment Board, IMS was able to contract the services of Intellisource International. Intellisource assessed their competition and evaluated competitive product positioning, messaging and best practices. They helped guide the management team through a strategy session that defined the company’s new competitive position and developed a message that would capture their market’s attention.

With the assistance provided by the project team and the grant, IMS was able to access $50,000 in matching grant funds to assist in leveraging a transformation of their business. Since completing the training program, IMS has redefined their business, branching out from solely being an engineering design solutions company, to growing a new business line as a high-end contract manufacturer. The company now provides solutions for the military, several Original Equipment Manufacturers and other world-class manufacturers. MORE

Hollingsworth & Vose Company

Hollingsworth & Vose Company is an international leader in the development and manufacturing of specialty papers and nonwovens that benefit the air that people breathe, the cars they drive, the clothes they wear, and the places where they live and work.

While the company has been successfully developing products to meet customer needs for over 160 years, executives at Hollingsworth & Vose recognized a need to streamline and revitalize its R&D process in order to fight off growing competition.

The company brought in Time Wise Management Systems (TWMS) and Massachusetts Manufacturing Extension Partnership (MassMEP) to help identify opportunities to change the basic development process and make it more effective. With support from a US Department of labor High Skills Training Grant, administer through the Central Massachusetts Regional Employment Board, the project team conducted an enterprise assessment and a technology road-mapping project, focusing on the R&D and product development process. The team identified ways to help them transform the R&D process so they could get those products to market in a more timely fashion. MORE

Sea-Watch Technologies

Since 2002, Sea-Watch Technologies has developed and deployed integrated monitoring and communications equipment for client use in marine applications. Recently, the Sea-Watch team developed an advanced remote command and control architecture dubbed “SIS”. The SIS combines the Internet, Artificial Intelligence and GPS into a seamless tool for use in alerting owners and/or fleet managers of “states” of on board systems. To successfully inform marine operators of the SIS it was pertinent to discover effective marketing strategies to promote the configurable ‘command and control’. Sea-Watch also sought methods to create complete and meaningful demonstrations of the product for the client.

In order to accomplish these marketing tasks, Sea-Watch strengthened its partnership with Interface and Control Systems, Inc. (INS) in Indialantic, Time Wise Management Systems (TWMS), and Florida Manufacturing Extension Partnership (Florida MEP), as well as tapped into an H-1B Advanced Manufacturing Grant funded by the US Department of Labor and administered by the Brevard Workforce Development Board. The funds supplied the company with small assessment of Sea-Watch’s products and business practices. As a result of the assessment and partnerships, ICS staff trained and guided Sea Watch employees in the development of appropriate software models able to simulate control systems for prospective clients. From these sessions Sea Watch developed a configurable web based GUI, the “Marine Monitoring and Alert System Preview”. These demonstration models, an excellent marketing tool, will be mentored further in the future on how to use additional complimentary grants to accelerate such efforts. MORE

NDH Medical, Inc.

NDH Medical, Inc. (NDH) has delivered unique extrusions and contact manufacturing services to the medical industry since 1994. The company strives to stay ahead of the curve and provide the most advanced products to its clients. In particular, they provide a variety of tubing with unique physical properties, as well as a line of elastomeric balloons for use in the manufacturing of medical products.

In NDH’s search for ways to improve its catheter balloons, collaboration with the Time Wise Management Systems (TWMS), Florida Manufacturing Extension Partnership (Florida MEP), and the University of South Florida (USF) began. Florida MEP provided NDH with a H-1B Advanced Manufacturing Grant, funded by the US Department of Labor and administered by the Brevard Workforce Development Board, allowing NDH to initiate a mini-assessment of the company, its products and business methodology. Based on these results, NDH resolved to hiring mentors for NDH employees in the area of medical polymers and polymer constitutionals beneficial to the company. The H-1B grant supported the training of NDH employees on the use of tear strength materials. This knowledge gave NDH the ability to expand its balloons to a size and order of magnitude greater than its existing product. Following this discovery, a process for consistently producing balloons was prototyped in parallel with characterization of the new material. MORE

Flotation Technologies, Inc.

A world leader in the design, manufacture and marketing of deepwater buoyancy systems using high-strength Flotec™ syntactic foam and polyurethane elastomer products, Flotation Technologies, Inc. provides products for the offshore oil. The world’s largest manufacturer of oceanographic subsurface buoys for current meter studies and global climate change research, the company also provides products for underwater robotic vehicles and offshore production and drilling.

Although Flotation Technologies has only a few competitors in the world, they have large competitors and it is difficult to compete on a cost basis alone. The company recognized that it needed to reduce its lead time by speeding up the process of providing quotes and flowing the product through the plant. MORE

Mobile Outreach Skills Training® (M.O.S.T.) Program

Maine Machine Products

The Maine Machine Products Co. of South Paris has six new machine operators thanks to the Mobile Outreach Skills Training Grant (M.O.S.T.®), a six -New England state innovative program funded by the U.S. Department of Labor and administered by the Maine Department of Economic and Community Development.

“The six individuals hired out of the M.O.S.T.® training are contributing associates after just a few weeks of on-the-job training,” said Thomas Galley, chief operating officer at Maine Machine Products Co.

Non-traditional workers were recruited by the South Paris Career Center to fill the spots. Most of the newly trained machine operators were unemployed or under-employed individuals in another profession altogether. The program is intended to offer participating companies a competitive edge in the future. A machinist is highly skilled, however, with modern CNC equipment, it is not necessary to have a skilled machinist on each machine. MORE

Keene, New Hampshire, Office of Employment Security

When you’re out of a job, all you can think about is how you’ll make a living. When you’re a manufacturing company with a shortage of skilled workers, you wonder how you’ll ever get your projects done. The New Hampshire Manufacturing Extension Partnership (NH MEP) understands this problem well, and by partnering with the Keene Office of Employment Security, they are helping solve it.

When the M.O.S.T.® (Mobile Outreach Skills Training®) mobile training unit arrives at the Keene Office of Employment Security on May 21, ten local out-of-work men and women will be trained in order to secure highly skilled, computerized manufacturing jobs with three New Hampshire companies.

M.O.S.T.® is a U.S. Department of Labor pilot program launched in the six (6) New England states and helps local manufacturers fill a rapidly increasing number of vacant Computerized Numerical Control (CNC) machine operator positions. The mobile training unit, equipped with computer terminals and interactive machines, will be in Keene for two weeks as trainees are fast-tracked into new careers. MORE

M.O.S.T.® Program Press Clippings

A learning machine - "Kennebec Journal" (Maine)
Starrett teams up for training program - "Greenfield Recorder" (New Hampshire)
Rich Industries (Maine)
Classroom on wheels offers precision machine training - "Morning Sentinel" (Maine)
South Paris Company Gets the MOST Out of New Program - "Business Focus" (Maine)
Manufacturing jobs training bus rolls in - "Somersworth Union Leader" (New Hampshire)
R.I. needs machines but has few qualified applicants - "Providence Journal" (Rhode Island)
Mobile Training Program At The L.S. Starrett Company (New Hampshire)
South Paris company gets the MOST out of new program - "Mid State Advertiser Democrat" (Maine)
Solving our critical shortage of machinists - "Machining"
Fast track to new skills Program that started in Maine churning out machine operators - "Sun Journal" (Maine)

Lean

Spirit Electronics, Inc.

Spirit Electronics, Inc., a Phoenix-based company, is a distributor specializing in supplying products and services to the military/aerospace industries. Since Spirit continuously adds new franchises to their distributor base, the company not only wanted to maintain their outstanding customer service, but find ways to improve on order and quality processes as well.

They partnered with Time Wise Management Systems (TWMS) and Arizona Manufacturing Extension Partnership (Arizona MEP) to facilitate a three-phased approach project. The project team performed an enterprise assessment to identify the company’s strengths and opportunities for improvement. Secondly, utilizing Time Wise® Value Stream Mapping System, they began mapping their present process in their order management office to establish their current state. The mapping process helped Spirit to envision its future state and recognize ways to improve the way they process orders, reducing a 32-step process to only 14 steps. Finally, through a short burst of activities resulting in incremental but constant improvements, the staff at Spirit was able to create standardized workstations with a visual, more efficient and relaxed working environment. MORE

Pelican Wire Company, Inc.

Pelican Wire Company, Inc., a small Naples manufacturer, moved all of its operations from four locations into one centralized building. The moved was likened to moving four different people and all of their belongings into one apartment.

However, officials of the manufacturer of custom insulated wire for a number of applications, including use in military helicopters saw an opportunity to reassess how they conduct their manufacturing processes and look at ways to streamline operations while improving sales and saving money.

Working with the Florida MEP, staff and management conducted a Time Wise® Value Stream Management System session. They were able to identify about half a dozen areas where they could make changes, eliminate steps and improve productivity and quality. MORE

L-3 Henschel

L-3 Henschel has been the leading manufacturer of control, navigation and communications equipment for the US Navy and commercial maritime industries, providing systems that meet a wide range of military and commercial needs. Their Quality Assurance Program meets strict requirements of quality standards, and all products undergo a series of rigorous and environmental tests to ensure reliable performance.

In order to maintain their stellar reputation in the business and keep up with high demand for equipment, Vice President of Operations John Sewall wanted to make sure all employees were trained in their engineering design process. With a grant from the Massachusetts Workforce Training Fund, the company was able to team with the Massachusetts Manufacturing Extension Partnership (MassMEP) to implement the Time Wise® Principles of Lean. MORE

Auburn Concrete Company

Superior Concrete, manufacturer of precast concrete products, decided to learn more about Lean Manufacturing. Peter Allen, production supervisor of the Auburn division, was convinced that Lean Manufacturing was important to his company. Incorporating Time Wise® Principles of Lean Manufacturing would empower the company’s employees to do the best jobs possible.

"As a result of the Lean Manufacturing we have experienced savings of approximately $250,000," said Allen. "We feel this is excellent considering we have only been doing Lean for 18 months." MORE

Manchester Printer Cartridge Company

Reliable Technologies is always looking to make some cost-reducing changes at its company. Manufacturer of printer cartridges and fax machines, Wayne Justason, vice president of manufacturing, recognized an opportunity to incorporate positive modifications to keep up with their production demands.

Familiar with Time Wise® Principles of Lean, Justason knew the New Hampshire Manufacturing Extension Partnership (NH MEP) was an expert in implementing Lean. In implementing a Time Wise® Value Stream Management System session, the workflow was streamlined, and three work areas were combined into one work cell, reducing the time and distance of the production process. "As a result, we have been able to manufacture about 120 cartridges in 6 hours as opposed to the 80 we were making before. That’s a 50 percent productivity increase," said Justason. MORE

Bensonwood Homes

Over 30 years ago, Tedd Benson brought innovation back to homebuilding by combining cutting-edge thinking with craftsmanship. Benson revitalized the traditional home art of timberframing, and today, Bensonwood Homes is a national leader in residential and commercial timberframe buildings. However, their collaborative approach to building homes and building on their skills lead them to seek continued improvement.

They engaged New Hampshire MEP to implement Time Wise® Principles of Lean Manufacturing, a systematic approach to eliminating waste, reducing manufacturing costs, while increasing productivity. MORE

Eastman Industries

Eastman Industries’ owner and president, Nicholas M. Nikazmerad, recently decided to expand his self-propelled lawn mower manufacturing company by purchasing Ingersoll Tractors of Wisconsin. He knew it was a great idea to expand his company to riding mowers, but he had concerns about how to absorb the company into his, where to locate his manufacturing facility, and what was the best way to set up his shop to be as efficient and profitable as possible.

“Relocating the Ingersoll Tractor Co. from Wisconsin to our new facility in Maine proved to be a major task,” said Nikazmerad. “The scope and complexity of dismantling the manufacturing operations in Wisconsin and reconstituting them in Portland was more difficult than anticipated.” MORE

Brockway-Smith

When the Portland, Maine Brockway-Smith facility officials had a challenge meeting the demands of their customers, they recognized the company needed the assistance of the Maine Manufacturing Extension Partnership (Maine MEP) to implement Lean methodologies.

Although the manufacturer of doors, windows, and specialty millwork was limited by its square footage, the goal was to increase production while utilizing the same manufacturing space.

Implementing Time Wise® Principles of Lean Manufacturing, the company optimized facility layouts using new automated equipment in a flexible manufacturing cell orientation, allowing Brockway-Smith to adjust to changes in daily demand by quickly reorganizing their capacity on an as needed basis. MORE

New England Castings

New England Castings foundry president owner, Walter Butler, recently agreed to provide components and sub-assemblies to a railroad hardware manufacturer that provides products for a major city subway system. The value of Butler’s purchase orders for the subway system job is in excess of $500,000 over a 12-month period.

New England Castings, an investment-casting foundry that uses only environmentally friendly water-based slurries in the production of its shells, had to consider adding 3,000 square feet to the existing of 9,000 square feet facility. However, he wanted to be sure the current space was being used as efficiently as possible.

The company engaged Maine MEP to implement the Time Wise Principles of Lean training and conducted several rapid improvement workshops throughout the factory, focusing on organizing and labeling the materials in the area in order to save 20 percent of the work time, and to gain back 50 percent of the usable space for manufacturing processes. In one instance, a task that normally took 45 minutes was reduced to 15 minutes, and 4,000 feet of traveling throughout the facility each day was eliminated. MORE

Stellar Industries

Stellar Industries makes miniaturized heat conductive ceramic blocks similar to circuit boards which are made-to-order for customers in the telecom, biomedical, and defense industries. As demand for their products was increasing, management recognized a need to more efficiently manage their production process.

Stellar engaged the Massachusetts Manufacturing Extension Partnership (MassMEP) to help streamline their performance on the production lines MassMEP then helped the company obtain a Workforce Training Grant through the Massachusetts Department of Employment and Training to finance the program and implemented Time Wise® Principles of Lean training throughout the company. MORE

FLEXcon

Determined to make the future of FLEXcon as successful as its past, top executives from the company are always looking for ways to maintain their competitive edge. After attending Massachusetts Manufacturing Extension Partnership (MassMEP) Lean Manufacturing simulation training, FLEXcon’s management team decided to implement the Time Wise® Principles of Lean.

“The timing of FLEXcon completing our Lean initiatives coincided with skyrocketing energy, raw materials and fuel costs. Had we not implemented Lean when we did, the increasing prices would have hindered our business substantially,” said Tom Kubacki, FLEXcon director of coating technology and production control.
MORE

Vitarich Laboratories

Vitarich Laboratories has been a pioneer in the research, development and worldwide distribution of premium nutritional products.

When Vitarich became cGMP certified, the company experienced rapid growth. As the company expanded, they continued to need more space, which resulted in Vitarich’s operations being spread out among several buildings, creating workflow issues.

Vitarich’s executive vice president, Craig Waldinger brought in Florida MEP to introduce the Time Wise® Principles of Lean Manufacturing. A Time Wise Value Stream Management System session was facilitated to map the flow of work through the production line, identify gaps and then implement changes that would have the greatest impact. MORE

Hanger Prosthetics and Orthotics

Hanger Prosthetics and Orthotics National Fabrication Center in Orlando was recently recognized by the Manufacturers Association of Central Florida as Manufacturer of the Year.

One of the keys to Hanger’s Orlando National Fabrication Center winning this award is the success the center experienced as a result of implementing Time Wise® Principle of Lean Manufacturing through a collaborative effort with the Florida MEP. MORE

AMCO Water Metering Systems Inc.

AMCO Water Metering Systems Inc., a leading provider of innovative metering products and solutions partnered with the Florida MEP and received approval from the Incumbent Worker Training Program (IWT) for $20,000 in grant monies to be used to train their workforce in Time Wise® Principles of Lean Manufacturing.

Despite having a comprehensive portfolio of advanced metering products and meter reading solutions, AMCO’s president, Blake Snider realized that in order to sustain the company’s growth, the business needed to embrace Lean Manufacturing, an initiative focused on continuous improvement and elimination of waste. MORE

New Hampshire Industries

New Hampshire Industries (NHI) is a leading supplier of pulleys, spindles, and other pulley-like products, and is committed to product innovation and customer satisfaction. When NHI formed more than 45 years ago, the company primarily made idler pulleys. Since then, the manufacturer has expanded its production business to drive pulleys, cast pulleys and sheaves to better serve their clients’ needs.

"We definitely had a production peak in the winter and spring, but were looking to keep a steady, more efficient pace year-round. We had done some training on basic lean principles on our own, but we knew we could use some additional training and guidance from someone outside our company," said J. Todd Miller, Company President and CEO of NHI. "John Simpson of the New Hampshire Department of Resource and Economic Development introduced us to Jane T. Ely, project manager at the NH Manufacturing Extension Partnership (NH MEP). Jane rolled up her sleeves and got right to work with us, and also assisted us in obtaining a Workforce Training Grant to defray training costs." MORE

Lean Government

Maine Department of Labor

In 2004 Time Wise launched a project with the Maine Department of Labor to implement an extensive, agency-wide lean training program. The department faced dual challenges – funding cuts as well as an aging workforce with more than 50 percent of its employees eligible to retire within five years. Time Wise succeeded in helping the department accomplish more with less.

Beginning by introducing the concepts and tools of lean to more than 600 employees, the Time Wise team of specialists has gone on to hold more than 35 value stream mapping sessions to date. We also established a Continuous Improvement Parishioner (CIP) training program in order to ensure that the initial momentum for the initiative was carried forward. Approximately 30 department employees were trained in advanced lean concepts and facilitation skills.

Within the first 18 months of the project, the Maine Department of Labor realized savings in excess of $1.1 million and identified an additional potential savings of more than $3.6 million. MORE