Doran Scales Inc.  |  20 employees  |  www.doranscales.com

Doran Scales is a digital scale manufacturer located in St. Charles, Illinois.

SITUATION

As competition began to grow and internal processes became more cluttered, Doran Scales faced the realization that they could no longer operate as an “80’s” manufacturing company – living off of high profits, consistent customers, and minimal demand for quality products. Mark Podl, CEO, knew the operation needed significant improvement and by starting with the shop floor operations he could begin the transformation to an up-to-date, lean and quality-minded, 21^st century organization.

SOLUTION

Mark first engaged IMEC in setting the framework for how they would approach and prioritize the many improvements through education on the fundamentals of lean manufacturing. By then identifying the need for a shop floor “clean-up,” the Doran Scales team alongside IMEC laid out a plan for an improvement to the physical plant layout through several Kaizen events. By streamlining manufacturing processes and organizing tools and people in a more efficient flow, the team was able to kick start the journey to lean – each individual owning their incremental improvements and committing to the new way of working. “Pushing past the initial stigma of needing to be ‘fixed’ was difficult for some,” said Podl, “but having the guidance of individuals [IMEC] with experience has been extremely helpful. They provided us with the support we needed to get from point A to point B.”

Reflex Fitness Products was given birth in 1990 through the creative forces of Craig Askam and Mike Adolphson.  It was a combination of Mike’s sales, gym and design experience along with the collision of Craig’s machining and manufacturing expertise that proved to be an incredible combination. Reflex’s handcrafted, functional, biomechanically correct designs tagged with their competitive pricing equals some of the best values in the industry.

All of Reflex’s equipment is built in house and Reflex takes great pride in making equipment that proudly stands as built in America. Each piece of equipment begins with the planning process and then the application of raw materials.  Looking for custom built equipment? Reflex can build whatever you want! It is what sets Reflex apart.

Moderne Beverages believe that choosing a beverage shouldn’t be difficult. Driven by the lack of clarity and transparency of beverages on grocery store shelves, Moderne Beverages was formed. They strive to craft products with integrity, transparency, nutrition, and knowledge.  At the heart of their products are probiotics: microorganisms that benefit from the ingredients in our beverages, and consumers benefit from their presence when ingested in the right amount. 

The Chicago-based company takes great pride in their ability to show-and-tell all of their steps, ingredients, process aids, and back up their choices with distilled-down info. Moderne Beverages wants customers to be informed to make the best decision for themselves.

More than a third of workplaces did not submit... Are you on the naughty list?

By the end of 2017, select employers were required to submit 300A forms containing 2016 data. Unfortunately for OSHA, only two-thirds of the anticipated 350,000 submissions were recorded. These organizations are now facing potential scrutiny and fines for these "other-than-serious" citations, and will be conducting inquiries until June 15, 2018.

Did you find yourself on the OSHA target list for not submitting? As a reminder, establishments with 250 or more employees that are currently required to keep OSHA injury and illness records, and establishments with 20-249 employees that are classified in certain industries with historically high rates of occupational injuries and illnesses are required to submit. 

Written by Rick Winkler, IMEC Technical Specialist 

Throughout my 20+year journey with continuous improvement, I’ve helped individuals experience a wide array of necessary “tools” for executing lean continuous improvement (CI). But none are perhaps more integral for success than standard work.

Standard work is likely the most powerful—but least used—lean tool available for individuals and organizations hoping to make change and inspire efficiency improvements. By documenting the current best practice, standard work creates the baseline for kaizen or continuous improvement events. It is important to understand that the baseline standard created initially is expected to be improved upon (hence continuous improvement); the new standard becomes the baseline for further improvements, and on and on.

Advantage Components, Inc.  |  60 employees  |  www.aciwires.com

ACi is a contract cable and wire harness manufacturer located in Joliet, Illinois.

SITUATION

In early 2014, Advantage Components, Inc. (ACi) began to see exponential growth in sales and subsequent production. But with space constrained in their current facility, the company knew it was time to make room in the existing facility or expand beyond their four walls. ACi leadership, had previous experience working with the principles of lean manufacturing and were interested in committing to increasing efficiencies in the current space before committing to a new facility. Through a quick online search of experts in the field of lean, ACi discovered IMEC.

Metamora Industries started out in 1929 as a simple machine shop with a simple goal: to give their customers the highest quality products and service. While their original goal has not changed over the years, they have grown to include an extensive list of manufacturing capabilities-offering machining, fabricating, tube bending and more, all from one reliable source.

Metamora Industries is proud to have achieved the industry's highest standards for continuous improvement, defect prevention and waste reduction. They stand apart from their competitors with their ability to anticipate and act on what customers need in the future.  To aid with this process they constantly update procedures and training.  Metamora Industries is equipped with solutions to help get customers where they want to go.

At Illinois Window Shade Company (IWS) their superior shade systems effectively manage solar heat and glare, providing outstanding levels of comfort, energy efficiency and privacy.  Home of the PowerMove® and SmoothMove® solar shade systems, IWS manufactures superior shade systems that effectively manage solar light and heat transmissions.

Since 1905, IWS has built a reputation within the architect and design community as a trusted source for custom shade solutions for commercial and residential projects.  The company has completed projects all around the Chicago area.  Their mission to provide custom solutions for solar control challenges through a simple, efficient customer service process using proven manufacturing processes.

Written by Roger Shrum, IMEC Regional Manager

In my work with manufacturers, I’ll encounter leaders who are frustrated with the slow pace of implementation of their continuous improvement programs.  They are concerned that they are not seeing the payback they were hoping for.  What I share with them is sometimes unsettling: Many enterprise-wide lean deployment programs become stalled because the top manager in the company has not clearly articulated his/her personal vision and committed to making it successful.

In one example, a company I was advising faced chronic late delivery problems, which jeopardized its reputation with longstanding customers and opened the door for its competitors to take business away.  The company was forced to work significant overtime and expedite production just to stay in the game. This company had a history of waiting for a downturn in business to shore up its delivery performance. Along the way, they “dabbled” in implementing lean methods, but as orders increased, a full lean implementation was shelved.  In retrospect, these well-meaning, busy leaders now realize that they may have missed an opportunity for significant growth by not positioning the company to adequately meet customer needs during the upside of the cycle.  

Whitepaper and executive summary provided by the ISA, a technology and workforce training partner of IMEC.

Effective cybersecurity management is essential for all organizations, regardless of size. There are many standards and guidance documents available to help organizations determine a way forward.

The ISA whitepaper “Industrial Cybersecurity for Small- and Medium-Sized Businesses” is intended to provide a starting point for SMBs, particularly those that manage industrial processes and employ some level of automation. Specific examples include SMBs in the chemical, water, or wastewater treatment sectors.

While it is generally accepted that Operational Technology (OT) system security requires different or additional measures than general-purpose Information Technology (IT) system security, it is also true that smaller companies might have difficulty implementing much of the available guidance.

National Coatings Inc. is a leading supplier of a very diversified selection of high quality, peak performance coatings for use on metal, plastic, tubular, paper & wood surfaces.  The company's innovative technical development system utilizes the latest advance quality planning techniques to provide the user with products designed for customer and industry specific applications for performance requirements.

National's team of highly trained, dedicated and experienced technical and application specialists provide support for the latest ASTM testing to customer and industry standards.  National Coatings provides not just a product, but a company with a mission to provide the ultimate in quality, support and customer services.

E2 Manufacturing Group is a full-service plastic injection molding and contract manufacturing company. They proudly manufacture volume (low/high) production, and prototype parts and assemblies for a wide variety of clients and markets. Since 1998 they've pursued manufacturing perfection with a precise mix of quality, service, delivery and price.

E2's 25 years of experience in the molding, tooling, prototyping, and engineering fields guarantee 100% customer satisfaction. Their services include turn key molding, automated assembly solutions, as well as continued dedication to new technologies. E2's goal is to stay on the cutting edge of technology in the manufacturing industry by providing both the finest manufacturing equipment and people in the world.

Written by Ken Wunderlich, IMEC Technical Specialist

Food Safety rules, regulations and requirements apply to many types of companies, even some you might not think of, like ingredients and packaging suppliers, the packers themselves, warehousing and storage providers, trucking and logistics partners… every company that handles food on the journey from farm to table.  If your company handles or touches products in the food chain, or if you want to get into that industry, there are strict rules you have to play by, but they don’t need to be overwhelming.

Companies big and small make important contributions putting food on the table locally and worldwide.  Small farmers, for example, serve a vital role in supplying local farmers’ markets and retailers, where Food Safety management is a little less daunting because they literally control the process from the farm to the shelf.  You’ve heard it before, and it’s true:  Small Farmers are the backbone of America, and many make a good honest living supplying their local communities.