Imagine a company that’s been crafting signs for over 100 years. They started with simple rubber stamps and evolved into a leading provider for major industries like hospitals, warehouses, and hotels. That’s the story of one of our recent clients—a business built on a legacy of quality and a commitment to innovation. But even with such a strong foundation, they knew there was more potential to unlock.
The Challenge: Standing Still Wasn’t an Option
This isn’t a startup struggling to find its footing. This is a company with a century of success behind it! But they recognized that in today’s fast-paced market, even a legacy business needs to adapt and streamline. They decided to take a bold step: implement Lean methodologies at their Denver facility. They knew to stay competitive and to continue delivering on their promise of innovation, efficiency, and quality, they needed to optimize their operations.
Our Strategy: A Blend of Lean Thinking and Targeted Training
We didn’t just walk in with a one-size-fits-all solution. We partnered with them to develop a strategy tailored to their unique needs and history. Our approach included:
- Lean Training: We immersed their team in the principles of Lean Thinking. They learned how to apply concepts like “Pull” to achieve “Flow,” and how to identify and eliminate all forms of waste. This wasn’t just theory; it was about practical application.
- Value Stream Mapping: This powerful tool helped them visualize their entire operation from end to end. They could SEE where bottlenecks existed, where improvements could be made, and which changes would have the biggest impact on safety, quality, cost, and delivery.
- Training Within Industry (TWI) – Job Methods (JM): We introduced Job Methods to standardize their production processes, ensuring reliable, repeatable results. This not only improved efficiency but also created a framework for employees to actively suggest and implement improvements.
The Outcomes: Growth and Transformation
The results speak for themselves. By integrating Lean training with strategic consulting, our client:
- Boosted Profitability: They saw a significant increase in their bottom line.
- Ensured Scalability: They’re now positioned to handle increased demand and growth without compromising on quality or delivery.
- Maintained On-Time Delivery and Customer Satisfaction: They continued to deliver exceptional service, keeping their long-standing clients happy.
Preliminary Outcome Metrics (First 12 Months):
- New and Retained Sales: $8 Million
- Cost Savings: $1.9 Million (in labor, materials, energy, overhead, and more!)
How Lean and TWI Made the Difference:
- Empowered Employees: They gained a deeper understanding of Lean principles and how they could contribute to improvements.
- Visualized Processes: Value Stream Mapping allowed them to see the big picture and identify key areas for optimization.
- Standardized Production: Job Methods ensured consistency and quality, while also encouraging innovation from the ground up.
Ready to Transform Your Business?
Whether you’re a century-old company or a rapidly growing startup, Lean methodologies and TWI can help you unlock new levels of efficiency and growth. We specialize in providing tailored training and consulting solutions that empower your team and drive real results.
Contact us today to learn how we can help you achieve similar success!
