Lean Success Story

Improvements at FLEXcon Help Offset Rising Energy Costs
MassMEP Lean Manufacturing Techniques Also Help Improve On-Time Delivery

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.

FLEXcon focused on improving a number of areas including drastically improving on-time product delivery in their Slitting Department which is now averaging close to 100 percent on-time delivery. The company identified several areas to make upgrades that would improve delivery time. Utilizing the Time Wise Value Stream Management System, the mapping process identified a lack of visual scheduling of production needs that led to bottlenecks and delays.

“Lean training and implementation has been great for FLEXcon because it is often so simplistic that many of your answers were right there in front of you,” said Howard Letendre, Director of Finishing Technology at FLEXcon. “The MassMEP helped us identify and implement improvements that have had a positive result on our work and the bottom line of our company.”