MANUFACTURING
CASE STUDY
Industry: Rubber
Location: Missouri
Year: 2015 - Present
PROJECT RESULTS
20% annual revenue growth with 50% reduction in average workload for the owners while improving product quality and increasing margins.
SITUATION
A family-owned manufacturer of rubber and plastic products since 1994, known to its customers for their production quality and knowledge, struggling to maintain their standard of excellence as they grow.
CHALLENGES
- Work instructions and previous run data were kept on paper and difficult to access
- Data insights and measurements were missing or time-consuming to produce
- Job scheduling conflicts were preventing on-time deliveries
- Staff was experiencing overlapping tasks and unclear goals and deliverables
- The four software programs for ordering, vendor interaction, receiving and shipping, usage, and production were not integrated
SOLUTIONS
- Implemented JobBOSS with custom built modules
- Built a cloud-based web application to generate estimates and quotes tied into real-time data. Customized their ERP system by building a process SPC job quality control system that captures current data and displays historic data.
- Automated quoting production directly into instantly-generated editable Word documents and PDFs
- Created a drag-and-drop scheduling tool that helped visualize the shop schedule live based on actual production speeds
- Calculated supplies and raw material requirements dynamically based on scheduled work to provide insights to the shop floor
- Implemented Search Engine and Social Media Marketing
SCRAP RATE WAS DECREASED BY 7% TO <1%
a savings of $57K per year, 2% of revenue or 11% of materials
NON-CONFORMANCE RATE WAS REDUCED BY 82%
resulting in higher confidence of quality for customers
QUOTE TURNOVER TIME WAS LOWERED BY 70%
by completely eliminating non-quote related work such as formatting, text editing, and retyping