Deere-Hitachi company faced a difficult question: invest in an expansion or increase imports of excavators from other Hitachi facilities throughout the world.
Late in 2012, Otto Environmental Systems North America Inc., an innovative plastics manufacturer, launched a strategic evaluation to efficiently increase its production output.
Rocky Mount Company Draka Elevator Products, Inc., joins the Economy, Energy and Environment Initiative.
In any organization, solid communication and time-sensitive operations are critical to overall success. To achieve a smooth and streamlined system, NC State Veterinary College participates in lean training from IES.
Think Medical, Inc., understood that business growth and innovation were directly linked to the company’s updated presence on the Web. IES worked with the company to modernize its website.
At Cane Creek Cycling Components in Fletcher, North Carolina, the mission is clear: Support all aspects of cycling worldwide—from professional racing to hobbyists and charitable organizations. Because of its commitment to enacting positive change with a sustainable, wide-spread approach, it was only natural for the company to ride down the path of the E3: Economy, Energy and Environment initiative.
NAIM’s OmniMax Roofing System has hopes of revolutionizing the roofing industry by creating shingles that are laid down with a hook-and-loop type of material instead of traditional nails.
Keihin’s Tarboro facility strives for excellence by pursuing the North Carolina Award for Excellence (NCAfE), adding lean training, and joining the IES Manufacturing Makes it Real Network.
ISO Certification Gives Tri-Tech Forensics an International Advantage.
Through a grant from the NWDB, NC State University’s Industrial Extension Service (IES) is partnering with Energy Solutions, a fellow program in the College of Engineering to facilitate the training, which is intended to reduce energy-related costs for participating businesses.
Defense products company, Esterline, makes workplace safety priority number one through safety training and monthly personal safety meetings.
Through a grant from the Northeastern Workforce Development Board, NC State University’s Industrial Extension Service (IES)partners with Energy Solutions to facilitate the training that reduces energy and ensures a structured plan for future energy use. Perquimans County Schools is the fourth recipient of the funds, the subsequent training, and the positive impacts.
Arcelormittal achieves OHSA’S 18001 certification and increases safety focus.
CarePartners Health Services has attained Level 2 status from the North Carolina Awards for Excellence. This designation signifies the company’s continuing efforts in the area of performance excellence.
Gaston County machine shop, Dallas Machine Company, Inc., seeks global markets through ISO 9001.
Ambulance maker AEV uses ExporTech™ to expand markets and profits overseas.
Moen makes lean a priority in its manufacturing operations and has realized nearly $1.5 million in savings directly attributable to lean.
Martin County food processor pursues E3’s suggestions for a combined economic impact to surpass $10 million dollars.
The Village of Pinehurst recently attained Level 2 of the North Carolina Awards for Excellence (NCAfE) program that recognizes exemplary business practices.
NC State University engineering extension specialists at the Industrial Extension Service (IES) helped Pearl Therapeutics Inc. navigate the complexities of environmental compliance, hazardous waste disposal and transportation, and to implement a safety program at their Trinity Road facility.
Southern Fabricators sees ISO 9001 training increase bottom line and create jobs.
ExporTech graduate turns lessons learned into export sales.
Duke University Hospital has become the first hospital in North Carolina to achieve the highest level in the N.C. Awards for Excellence program that recognizes exemplary business practices.
Composite fabrics firm implements quality management to diversify products.
Nester Hosiery had recently engaged with IES in the establishment of an environmental management system and achieved more business and profit by using less resources.
Giuseppe Guarino was told that getting ISO 9001:2008 certified in a mere 90 days had never been done, but the president of K-Flex USA decided to go for it anyways.
Caroline Glus and SRMC engaged the help of NC State University to help take their lean journey to the next level. That lean journey has helped provide a path to excellence, and it’s paying off!
RLM Communications earns ISO 9001:2008 certification after an 11-month long effort.
The movement of new product lines, coupled with the desire to reach broader overseas markets, prompted the North Carolina-based Columbus McKinnon facility to seek and achieve ISO 9000 certification.
CarePartners Health Services has received the Level 1-Involvement award from the North Carolina Awards for Excellence at NC State University. CarePartners is one of 3 healthcare facilities to receive the Governor’s Award of Performance Excellence in Healthcare for 2011.
CaroMont Health has received the Level 2-Commitment award from the North Carolina Awards for Excellence at NC State University. CaroMont is one of 3 healthcare facilities to receive the Governor’s Award of Performance Excellence in Healthcare for 2011.
The Southeastern Regional Medical Center (SRMC) has received the Level 2-Commitment award from the North Carolina Awards for Excellence at NC State University. SRMC is one of 3 healthcare facilities to receive the Governor’s Award of Performance Excellence in Healthcare for 2011.
Tri County Industries has earned AS 9100C certification through guidance from North Carolina State University’s Industrial Extension Service.
Charlotte-Mecklenburg Schools sends sixteen Green Belt hopefuls through NC State University’s Lean Six Sigma Green Belt program and they save the district $375,000 annually.
Ingersoll Rand has goals; transformational goals. Their first goal was to ‘lean’ their operations in 2008; currently the focus is to apply lean concepts and methodology to their processes and for 2010, they intend to tackle and improve plant flow.
By simultaneously acquiring two international quality standards, ISO 9001 and AS 9100, Petra Precision Machining & Design Inc. of Goldsboro became the first North Carolina company east of Interstate 95 to obtain AS 9100, the quality standard of the aerospace industry.
The Charlotte School of Law accepted a North Carolina Award for Excellence Commitment Award (Level 2) through the North Carolina Performance Excellence Program on August 29th.
Cape Fear Valley Health System Realizes Productivity Gains and Renewed Focus on Mission with Lean NC
After the Cape Fear Valley Health System (CFVHS) Sterile Processing Department was suddenly responsible for sterilizing and transporting up to an additional 1,800 instruments per day for outpatient facilities in their network, they turned to lean healthcare to improve their production process.
Motion Sensors, Inc. of Elizabeth City was experiencing difficulty finding workers equipped with problem-solving skills. Their lean goal was simple – add to the skill sets of their existing workforce. Their results were much broader.
On Friday, October 21st at 11:30 a.m., Johnston County Industries (JCI) accepted a banner from North Carolina State University’s Industrial Extension Service (IES) as recognition of their AS 9100C certification.
The owner of IndTool Inc., a machining manufacturer that makes thousands of precision parts each year, decided it was time for his company to go after ISO 9001 certification, the international standard of quality.
As local governments are asked to do more with less, they turn to the experts at NC State for guidance
Acme McCrary is a staple of the Randolph County economy, and has been for more than 100 years. The hosiery manufacturer supplies private labels as well as seamless garments to some of the biggest names in the business including Spanx, Gymboree, Banana Republic and Kohl’s. But it was the call from Wal-Mart, one of their largest customers that really made them think about the next 100 years.
NC State University’s Industrial Extension Service (IES) provided training, implementation assistance and pre-assessment audits to help Motion Sensors incorporate the AS9100 requirements as part of their existing quality management system.
Going for the ISO 9001 was part of that natural progression at R.A. Serafini Inc. The plastic injection molding company recently cut energy costs by 30 percent and is switching from hydraulic to electric-powered machines.
Saab Barracuda LLC: Provider of Camouflage Net Systems and Other Signature Managment to Enhance Surv
IES has partnered with Saab Barracuda, LLC, on a variety of projects including Six Sigma, growth strategies, and ISO 9001 internal audit training and preparation. Saab Barracuda reported more than $1.3 million in economic benefit based on projects facilitated by IES, the outreach function of the College of Engineering. Saab Barracuda was awarded the 1B4NC award for helping IES reach their goal of creating $1 billion in economic benefit to the state of North Carolina, in a campaign called 1B4NC.
ExporTech was developed by the U.S. Department of Commerce in conjunction with the U.S. Commercial Service and NC State University. It’s the ‘how-to’ program that helps small- to medium-sized businesses enter or expand into global markets. By limiting participants, the program offers a mentor that works one-on-one with companies over a 3-month period to develop a customized export strategy.
The Manager of Environmental Safety and Health (MESH) Certificate Program is designed to serve those responsible for safety and environmental issues within their plant. It is an opportunity to gain practical knowledge of relevant topics as well as a valuable credential.
Dynamic Systems’ materials provide impact absorption, comfort and pressure redistribution and can be found in everything from helicopter seats to horse saddles to helmets. The company which is now ISO 9001:2008 certified, can now ensure quality is ‘injected’ into each and every element before it leaves their plant in Leicester.
Banner Pharmacaps touts 3 black belts, 33 green belts, 95 red belts, and 225 white belts at their manufacturing facility in High Point. But this pharmaceutical company’s passion for belts is for function, not for fashion. Strict cGMP (current good manufacturing practices) dress codes require everyone on the production floor to “gown up” with hair covers, booties, and safety glasses – definitely not a chic style statement. Banner’s Six Sigma belts empower their workforce to concentrate on the processes behind their work.
With the help of North Carolina State University’s Industrial Extension Service (IES), Copernicus Group IRB (CGIRB) announced that it has received ISO 9001:2008 certification, affirming that the company’s quality management system meets the strict qualifications for the globally accepted ISO standard.
Tom Zone, executive vice president for Impact Fulfillment Services in Burlington, wanted his company’s largest customer to know the $100,000 savings they were passing along to them resulted from a commitment to lean principles. Other quarterly savings and other enormous checks followed.
Industrial Alloys, Inc. distributes and fabricates quality metal products—now they can even prove that quality. The company achieved ISO 9001/2008 certification with the help of the Industrial Extension Service (IES) at North Carolina State University.
Southeastern Regional Medical Center was recognized for achieving the commitment level of the North Carolina Awards for Excellence (NCAfE) today at a small ceremony.
Success will be measured by the lack of stress for patients and staff when Atrium Obstetrics & Gynecology in Raleigh moves into their new office later this year. The new floor plan and improved processes resulted from using lean principles that the physicians and staff learned from the NC State University Industrial Extension Service. Patients should notice a calmer atmosphere and better efficiency with their appointments, which means decreased wait times and more time with their provider.
“Business is not the same at home as it used to be,” said Paula Turlington, vice president of SII Dry Kilns in Lexington. “Even to be stable, we need new markets.” NC State University’s ExporTech program helped the company to secure more than $800,000 in new sales, but more importantly, from a new and unexpected market – Russia.
Capel Incorporated, a company built on innovation, understands the need for a quality, consistent product. The company enlisted the help of North Carolina State University’s Industrial Extension Service (IES) to improve efficiency and their competitive edge. The results are more than $2 million in economic benefit.
RLCB was the first non-profit organization to accept the 1B4NC award from North Carolina State University’s Industrial Extension Service (IES) on September 21st. RLCB, formerly known as Raleigh Lions Clinic for the Blind, reported more than $6 million in economic benefit based on services provided by IES.
NC State University helps increase new sales by 15 percent with help of management system.
Gates Corporation in Jefferson is passionate about continuous improvement. All it takes is a quick glance at the automotive belt manufacturer’s sparkling plant, with everything in its place, and a brief conversation with inspired employees to witness their commitment to improve quality, delivery times, and reduce costs.
Safelite® Glass Corporation wanted to reduce costs so they brought in the experts from IES to meet their goals of reducing costs through improved efficiency and productivity within their Enfield plant.
A sluggish economy provided the opportunity for The Timken Company in Asheboro to move faster to tackle the complicated task of integrating lean thinking into every aspect of the business.
The Brushy Mountain Bee Farm has doubled its sales and its workforce in two years, thanks in part to lean manufacturing principles taught by specialists with the Industrial Extension Service at NC State University. For reporting more than $2 million in increased sales, the company received the 1B4NC award from IES today.
The United States Coast Guard Aviation Logistics Center (ALC) in Elizabeth City provides aviation logistics that enable Coast Guard execution of search and rescue missions. One way to be sure those assets are most accessible for the organization’s mission is by improved efficiency, facility-wide; one of the tools they use, lean.
The group found eight areas within the hospital that could be the setting for a kaizen, the lean tool that quickly, often within a few hours or a day, brings rapid improvement.
Holt Sublimation Printing in Burlington has been chasing new ideas since it was born as a hosiery mill 62 years ago. The race continues, with two new products in the pipeline as a result of a process for finding and developing the most marketable idea, and turning it into a profitable product.
Shelby Elastics is defying the national recession—the company is busy, busy making some 1,000 plus different styles of elastics used in medical products; so busy they recently added a shift. How are they doing it?
Paul Brown’s great-grandfather founded W.A. Brown and Son in 1910 to make commercial grade freezers and coolers. They’re still making them today (using different methods) along with houses, garages, commercial car washes, campground cabins, and a contemporary one-of-a-kind energy efficient home created by a local architect certified in Leadership in Energy and Environmental Design (LEED).
The North Carolina State University Industrial Extension Service (IES) awarded the entire staff of Atlantic Veneer with the 1B4NC award as proof of their progress with lean manufacturing. In addition to the 200 plus employees and IES representatives, partners Tammy Childers from the Eastern Carolina Workforce Development Board and Perry Harker of Carteret Community College also attended the celebration.
What happens when you gather 50 people from eight countries into one room on Centennial Campus for a three-day idea generation session? When members of the MWV (MeadWestvaco) Personal Care Strategic Business Unit met for an ideation session in mid-October, they got more than 300 great ideas to choose from to energize their business: more ideas in less time than they had ever produced before.
Cable Assembly, LLC, in Graham can barely keep up with explosive growth and so many new orders that the 40,000 square foot facility can barely contain them. While the US economy founders and many manufacturing orders drop, Cable Assembly had to add a second shift.
Protective covering for wiring, plastic wine corks, golf club shafts, catheter tubing, seatbelt coverings, materials for car interiors and exteriors—these are but a few of the hundreds of products PolyChem Alloy, Inc. (PCA) of Lenoir helps make possible for Fortune 100 companies like SABIC Innovative Plastics and Delphi.
Elastic Therapy, Inc. a private label medical hosiery company, was awarded the North Carolina State University Industrial Extension Service (IES) 1B4NC award on December 4th, 2008.
Kathy Bryan, CEO of OE Enterprises, thanked the group of board members, staff and clients who gathered to accept the banner in late October, signifying ISO (International Organization for Standardization) 9001 certification from the North Carolina State University Industrial Extension Service (IES).
In late August of 2008, Innovative Laminations Company, Inc., accepted a banner celebrating ISO 9001 registration from the North Carolina State University Industrial Extension Service (IES).
On February 19, 2007, Oracle Packaging of Winston-Salem experienced an explosion in its aluminum rolling facility, severely damaging an 80,000 square foot building. The company manufactures aluminum foil, so had within its confines 100,000 pounds of molten aluminum, 30,000 gallons of fuel oil and 30,000 gallons of various solvents.
Fortunately, due to training they received from IES, not one of these hazardous materials escaped the property and no one was injured.
Chastain is not the first person to feel anxious about the ISO certification process. In fact many employees at AlphaTech in Fletcher had similar reservations, as do many companies. But looking at it from the other side, all agree it is well worth the journey. The contract machining, tooling, and progressive dies company received ISO 9001:2000 certification this August, and both the company and its customers are reaping the benefits.
Lean as a concept wasn’t new to the management team at CCI Conveyor Pulleys in Albemarle, but using lean tools and techniques to make their industrial conveyor pulleys hadn’t been tried. That first tentative step into lean has snowballed into a lean culture on the plant floor, including a full-time lean coordinator promoted from within.
When Snap-on Incorporated moved its power tool operations from Sioux City, Iowa, to North Carolina in 2002, it was an ideal opportunity to incorporate lean into the plant operations from day one.
Precision Hydraulic Cylinders, Inc. (PHC) located in Beulaville reported an economic value of $11 million by adopting both quality and environmental management systems with the help of the NC State University IES.
White tents, folding chairs and rounds with tablecloths marked that a celebration was afoot at Southern Prestige in Statesville. They were celebrating their AS9100:2004 certification with guests from the North Carolina State University Industrial Extension Service (IES).
Advanced Technology, Inc. chose to adopt a quality management system not based on the mandate of a client, which is typically the case, but to regain control of their production. Advanced Technology earned ISO 9001:2000 certification in March 2008.
Brainstorming and generating new ideas is daily business for a company making customized products. Yet, with a little help, Master Workholding of Morganton got a head start on their next new profitable projects with the Eureka! Winning Ways® program offered by IES. The company expects to save annually at least a half million dollars.
PCB Piezotronics, an upstate New York company, connected with the North Carolina State University Industrial Extension Service (IES) shortly after locating in Halifax, NC. They wanted to be lean. Lean is a continuous improvement tool that eliminates waste, no matter whether it is in movement, materials or inventory/work in process.
Ken Neves, general manager for privately owned commercial furniture manufacturer KI (formerly known as AGI), says no challenge is too big—except finding skilled workers.
“This was my dream, you let me have it, and I thank you,” were the words Bill Goodyear, president of his namesake, the Wm. Goodyear Co. spoke as he accepted the banner from North Carolina State University Industrial Extension Service (IES).
Achieving ISO 9001 certification is a major coup for any company, especially for a small company where everyone is stretched to the max. Although Genie Products of Rosman focuses relentlessly on product quality, this process challenged both management and the production team to take things to the next level.
In the conference room in the Catawba County Chamber of Commerce, Master WorkHolding officials are surrounded by the people that know them best including; industry liaisons from the Association of Manufacturing Technology, NC State University College of Engineering extension specialists and employees from the floor up to senior management.
Custom injection molder United Southern was in a financial crisis less than two years ago, as were many small and medium size injection molders due to intense competition from abroad. In 2005, the Forest City manufacturer of products such as automobile bumper components and child safety seats lost business, forcing layoffs. In truth, meeting monthly payroll sometimes challenged them. Then its President, Todd Bennett, made a bold move—a calculated gamble. The company made a serious commitment to lean enterprise transformation.
Mark Leonard, President and CEO, and Luanna Easton, Vice President for Performance Improvement, have been on a mission to increase the pace of continuous improvement to benefit patient outcomes at WestCare Health System. They decided to try lean.
VX Aerospace completed in 2 ½ months what generally takes up to 12 months; that is, achieving AS 9100 certification. VX Aerospace recently accepted a banner from the North Carolina State University Industrial Extension Service (IES), celebrating its AS 9100 certification.
PolyChem Alloy Inc. of Lenoir, a global supplier of polymer compounds and additives to a myriad of industries, recently obtained the global seal of approval for quality assurance known as ISO certification, providing market presence and sustainability.
Compaero celebrated its ISO 9001 certification with the help of North Carolina State University on October 11, 2007. The woman-owned small business that began in 1989 employs 16 people in Mooresville. Compaero is a distributor of Mil-Aero connectors and accessories. Connectors are used on aircraft or other defense applications, such as test equipment or missiles. The connectors carry power or data and help control such mechanisms as the flaps on aircraft.
Larry Isaacson, general manager at Cardinal Metalworks in Burgaw, is proud of his company. Cardinal Metalworks is a fast-growing manufacturer of precision-formed sheet metal components that provides services to industries from coast to coast. After the recent ISO 9001:2000 certification, it was time to celebrate. Last August Cardinal Metalworks was presented with an ISO 9001 banner from North Carolina State University to celebrate its accomplishment. ISO specialist Barbara Williams made the presentation amid the fragrance of good ole Eastern barbeque.
Oiles America, a manufacturer of maintenance-free bearing products, recently implemented a $4 million new process line as a result of ongoing lean improvements and a need to meet increased capacity. This gain from lean techniques allowed the company to reinvest in itself by adding jobs and the additional product line for the Concord facility, which is the largest manufacturing plant outside global headquarters in Japan.
BMW automobiles are advertised as the “ultimate driving machine” for good reason. These vehicles are built with care and great attention to detail. Continental Automotive in Fletcher plays a part in assuring these “ultimate driving machines” stop safely. Continental manufactures brake systems for the BMW X5 series, a new SUV, in their 264,000 square foot facility close to Asheville.
Berry recently reported an economic impact of $3.7 million based upon the gains they’ve made through their lean transformation with the help of the North Carolina State University Industrial Extension Service (IES).
Assumptions often get blown away when a company begins Six Sigma, which uses statistical analysis to methodically and objectively get to the root of problems. Windsor Windows in Monroe recently blew away several assumptions when it applied Six Sigma to its processes of making high-quality windows and doors.
In September of 2006, Carolina CAT set out to reduce its utility costs, which totaled more than $380,000 per year. Its 6 Sigma team (as Caterpillar spells it) embarked upon the arduous challenge and set a goal to reduce energy consumption by 5 percent.
The Loparex site in Eden has partnered with IES since 2005, beginning with the Six Sigma training of two Black Belts. In 2006, the Eden site turned to its IES extension specialist, Ken Hoover, when it was ready to start on its lean journey.