CASE STUDY 3: LEAN MANUFACTURING FUNDAMENTALS

Background

Client Three, established in 1957, is one of the country’s leading designers and manufacturers of premium foodservice equipment. The fryers, holding cabinets, rotisseries, combi-ovens and display merchandisers produced by over 500 employees at the company’s Eaton, Ohio headquarters are used in high-volume kitchens in over 100 countries around the world from quick service and casual dining restaurants to healthcare facilities, supermarkets and more. A privately-held, employee-owned company, Client Three is committed to growing its employees’ talents through extensive training and development ensuring it provides innovative, high-quality products to their customers around the globe.

Scope of Work

The Wiring Department of Client Three made a series of changes related to the location, the layout and the production processes employed in the department. In addition, the department expanded to a three-shift operation in order to scale production to meet growing sales demand. These changes have been difficult for the department as many of the employees were highly experienced and tenured and accustomed to the previous operations and processes. Gaining a fuller understanding of the methodology behind these changes and engaging employees in on-going continuous improvement effort within the department was identified by plant management as a key success factor for the group. Accordingly, Client Three requested Sinclair to develop and deliver a customized continuous improvement training program for all of the department employees.

Customized Solution

Sinclair Workforce instructors developed and delivered a customized, interactive continuous improvement training program for all of the department employees. Course curriculum included Lean Manufacturing concepts such as the seven types of waste, visual management systems, and single piece flow as well as topics on metrics and change management. Given the need to maintain production operations, the department’s employees were split into two groups for the training and two concurrent sessions were run allowing all employees to be trained at the same time. Additionally the training sessions were scheduled at times convenient to Client Three’s standard 24-hour work schedule allowing department employees to attend training with minimal disruption to their normal work schedules.

Outcomes

A total of seventeen department employees successfully completed the customized training course improving their knowledge and skills related to visual management, process flow and change management. The program allowed employees to have a better understanding of the newly implemented process and department layout helping the Wiring Department to adjust to current conditions and prepare for future growth. The training also allowed Client Three management personnel to gain feedback from employees to determine the effectiveness of the changes implement within the department while providing an opportunity to gain buy-in as well.

To discuss how Sinclair Workforce Development can partner with your organization, contact us today at 937-252-9787 or workforcedevelopment@sinclair.edu.