Precision Custom Coatings Goes Through a Lean Transformation

Background:

Precision Custom Coatings LLC manufactures and distributes interlining products. The company offers woven, nonwoven, and knitted fusible; needle punch and fiberfill; top fuse and sew-ins interlinings. Additionally, it provides adhesives, taping solutions, stretch linings, mattress and pillow encasing allergen-proof fabrics, and mattress protectors. The company caters to Filtration, bedding, automotive, and apparel markets. Precision Custom Coatings LLC was founded in 1987 and is headquartered in Totowa, New Jersey.

Challenge:

The cluttered environment of the factory floor and machine shop mitigated their process flows and could negatively impact production and the quality of work.

Solution:

Precision Custom Coatings recognized the need for Lean training in order to avoid hurting their overseas and domestic position with major customers. Precision Custom Coatings embarked on their Lean journey with the help of NJMEP. The first step in the journey consisted of an on-site assessment and a recommendation on how 5S System techniques followed by introduction of Lean concepts can help all production workers.

The 5S system is a Lean process that is organized around the following ideas: Sorting, Setting in Order, Shining, Standardizing and Sustain. The goal is to create specific places for paperwork, tools and equipment so that they can be located within 30 seconds. The 5S process relies on employees taking control of their work areas and suggesting and implementing improvements.

The Training Allowed Participants to:

• Describe the difference in workplace appearance and functionality before and after 5S process has been applied
• Perform an in-depth audit of workplace organization and standardization
• Organize the workplace by applying the concepts of sort, set-in order and shine
• Standardize procedures to maintain and control an organized workplace using visual controls
• Describe how 5S can help to improve workplace environmental health and safety
• Experience firsthand how 5S system reduces waste and improves productivity and quality

Results:

Satisfied with the training, Precision Custom Coatings began applying lean processes to the manufacturing floor.  Floor level training and improvements have helped minimize the time spent travelling between different work stations and around misplaced equipment, resulting in increased work efficiency.  They’ve worked at sustaining the changes they’ve made and to continually find new ways to make the process better, cleaner, and faster.

Over the past year, the company has increased significant growth gains, including:

• Increased Sales: $1,300,000
• Cost Savings: $150,000
• Savings on Investments: $50,000
• Workforce Practices: $99,000
• Employees Retained: 5

Mohammed Kovangji, Director of Operations said, “Precision Custom Coatings has seen growth in both sales and employee size since working with NJMEP. Our staff has put into practice lean manufacturing skills, and the training has had a lasting impact on our company’s day-to-day routine. 5S is far more than just straightening up and cleaning. It involves reviewing and re-thinking each employee’s activity, and making sure their work area supports their work. NJMEP’s assistance has proven vital to both our short and long-term successes.”