J&M Industries
J&M Industries Decreases WIP and Eliminates Overtime with Lean Manufacturing Implementation
"Implementing the lean principles has definitely increased the flow of goods through the plant. It completely eliminated working overtime each week, which is directly reflected in the bottom line. The professional team of Mike Scott and Brad Stump were outstanding in their presentation and in teaching us old dogs new tricks."
- Al Bourgeois - Plant Manger at J&M Industries
Company Profile: J&M Industries, founded in 1973, manufactures industrial tarps, shade cloths and freeze protection products. The privately owned company employs 100 people at their single facility in Ponchatoula, Louisiana. They sell their products internationally.
Situation: Al Bourgeois, plant manager of J&M Industries, attended a Lean 101 "Principles of Lean Manufacturing" course held by MEPOL in early 2002. After the course, Al requested that MEPOL review the flow of materials, product, and information for one of their industrial tarp product lines from a lean manufacturing perspective and assist in making any changes that would improve these flows. The company was experiencing problems that included a large amount of work in process, difficulty in finding orders, and difficulty in handling rush orders.
Solution: MEPOL project director Brad Stump reviewed the current flows of materials and information and the procedures for the product line. He also reviewed the facility layout.
After analyzing the results, Brad proposed layout changes with the implementation of a visual pull system for orders. He recommended the addition of a finishing sewing area that helped flow, as well. Orders were broken into "batches" based on linear feet of sewing to better control flow. Brad also helped develop a new incentive system to match the new lean system.
Results: The implementation of lean manufacturing principles at J&M Industries made it easier for the company to manage orders on the floor and handle rush jobs, which should help the company during its busy season. Product flow through the facility improved and work in process decreased by 25 percent. The implementation of lean manufacturing has allowed the company to eliminate working overtime, which is saving the company approximately $50,000. Additionally, J&M Industries now uses team-based goals based on company production goals.
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