Niagara Transformer Corp., Part 1
Niagara Transformer of Buffalo, NY, manufactures transformers for industry, power generation and transmission, and science and research applications. The growth of large, custom-designed transformer sales presented a production challenge for a space-constrained facility with no expansion options. TCIE launched a comprehensive Lean training program aimed at utilizing existing space more efficiently.
- Administered Lean overview training, including an introduction to tools, and a simulation exercise for all employees
- A team of 20 employees implemented 5S organizational principles and pull systems in virtually every plant area to reduce clutter and optimize the location of inventory and material supplies
- Engaged employees across all levels to embrace a problem-solving mentality
- Freed floor space in the plant and office by 50%
- Reduced turnaround time for CAD artwork by 50% and costs by 20%
- Waste reduction justified new equipment purchases to improve workflow
- Reduced material replenishment time from 1 hour to 5 minutes
- Added new email station to improve communications and expedite supply and raw material ordering
- Improved safety of the stacking area
- Standardized the design of several transformer components
Project ROI
How do we measure the impact of projects? It’s a mix of tangible, quantifiable savings with the more elusive “soft savings” – such as cost avoidance and improved customer satisfaction.