Company: STI-CO Industries, Inc. specializes in the design and manufacture of covert, tactical and public safety antenna systems. The majority of STI- CO’s customers are local, state and federal government agencies within the continental U.S., Canada and Mexico. They also partner with major high-profile OEM customers.
SITUATION: STI-CO’s ability to effectively service its customer base required improvement. Lead times were generally two to three weeks in a market that needed quick response, and on-time delivery averaged less than 50 percent. The company’s inventory turns were low and about three turns annually.
Management believed that a lean manufacturing approach could help address and resolve the operational issues. By innovating these processes, the company could better position itself to innovate their products.
SOLUTION: The first step was to introduce all employees to the principles of lean manufacturing. A full-day workshop provided basic knowledge in lean manufacturing methodology, and participants learned real-work application.
Insyte also worked with STI-CO to complete a high-level value stream map of the entire organization for both current and desired future states. This mapping exercise provided a comprehensive implementation plan utilizing the appropriate tools of lean manufacturing for each of their major product lines. Cross-functional teams worked to organize and understand new processes and practices; they then introduced and implemented these concepts into key production areas.
In addition, STI-CO and Insyte began the process of building and implementing an ISO 9001:2000 compliant quality system, which was reviewed with the entire STI-CO team, further establishing a foundation for understanding and progress.