Challenge
As the old adage goes, “The reward for good work is more work.” Casa Herrera’s decades of experience has earned them attention and interest across the industry. To keep up with customer demand, the company’s leadership decided to seek outside support and expertise. Their goal was to streamline processes, reduce manufacturing costs, and to promote a mentality of Continuous Improvement among their many long-term employees.
Solution
CMTC worked with Casa Herrera to develop a custom Lean/Continuous Improvement training program tailored to the company’s family-oriented workplace culture. The curriculum was project-based and the training was led by a CMTC instructor. Casa Herrera employees were divided into four teams and each team was given a specific area of responsibility as well as a measurable goal. As the teams learned about various Continuous Improvement principles, they were encouraged to apply them to their areas and to report regularly to the class on their progress.
The four teams included:
- Engineering Cycle Time Reduction: The focus of this team was to reduce the development time required from receipt of a customer order until engineering drawings were ready for release to the shop floor by 25%.
- Stock Room Labor Cost Reduction: This team’s goal was to reduce the monthly labor charges by stock room personnel. During this team’s close-out presentation, they were able to show cost reductions of 37%.
- Rework Reduction: This team, headed by Casa Herrera’s CFO, focused on identifying products or processes that were incurring excessive rework. Ultimately, this team was able to identify several products that had undesirable levels of rework.
- Problem-Solvers: This team targeted assembly processes in the shop. They started their efforts with an impressive 5S clean-up of the assembly areas. Then, they created a system to store kitted parts for assemblies in specially designated racks so that assemblers wouldn’t have to hunt for parts while building a machine.
At the end of the training program, all four teams successfully implemented a 5S system and visual controls within their areas of responsibility.
Impact
As a result of their work with CMTC, Casa Herrera estimates retention of all current jobs as well as the creation of 5-10 new jobs in the next 12 months. In addition, Casa Herrera forecasts that the training they received from CMTC will result in 10-20% cost savings for the company.
Casa Herrera Trainees on Graduation Day
“Our CMTC instructor was outstanding! We learned many different methods of validating information and asking questions. What was big for us was working together and understanding that by working as a team and being able to communicate, we can improve.”
— Mark Herrera, President
