Innovation in Progress

Doug Hanaway, Lean Project Manager, moves equipment back into place on the newly refurbished plastics production floor.

Tech Reinvests in Facility and Plans New Equipment

July 2009
While some manufacturer's are closing their doors and barely treading water during this economic downturn, Tech Molded Plastics, Inc. is taking advantage of it's financial strength to reinvest.

Reinvestment activities include re-flooring of both the plastics (pictured left) and toolroom operations, capital investment in a new mill and continued investment in lean manufacturing technologies.

Tech has developed a structured continuous improvement process for reducing scrap and waste while maintaining a clean, set-in-order environment. Customers, suppliers, and the people that influence the process day-to-day are part of the team that finds solutions.

An "Idea Log" was created to capture specific opportunities as they were identified by process auditors, flow maps, and strategic planning activities. The goal of the Idea Log is group related issues into select categories, prioritize, investigate, and assign a champion to take ownership of the idea.

Many of the items could be classified in more than one category but only one category could be chosen for each item. The group leaders helped to refine the list so priority issues could be identified. The idea champion's role is to identify a scope, objective, and timeline to see their idea through to the finish.

The rule of the system: Do not implement all ideas or tackle each category at the same time. Many ideas will be modified, tossed-out or developed into new opportunities. This is why the prioritization, investigation and solution stages are so critical to evaluate before implementation.

Communication boards are created to help share the idea, the objective, and progress. The bards are located in high traffic areas within the facility to make sure that success is visible.

Tech's simple process to follow that helps to change old habits:
1st - Create a sense of urgency. Reinforce why we must improve now!
2nd - A Champion develops the vision and strategy then guides the team.
3rd - Communicate the vision for understanding everyday!
4th - Empower others to act and capture more ideas. Make everyone responsible for success.
5th - Prioritize, produce short-term wins, and recognize success!
6th - Make it stick! Set-up audit schedules that catch people doing it right!

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