Available Plastics | Huntsville, Alabama
Company Information:
Founded 26 years ago in Huntsville, Available Plastics is a leading manufacturer in the PVC Industry. Available Plastics operations include plastic extrusions and injection molding in a variety of colors for custom orders. They manufacture sports equipment such as soccer goals and storage racks, as well as pool and spa products and central vacuum tubing.
Situation:
Available Plastics wanted to improve throughput time of a new product line with great potential for growth. The area of focus was final fabrication and assembly. In this area, extruded parts were drilled, components inserted, components assembled and packaged for shipping. The area was currently running with two operators and producing 12 units per hour. Planned demand required the area produce 20 units per hour; throughput must be improved without adding cost.
Center Assistance:
On the first day of a three-day kaizen event, the Alabama Technology Network at the University of Alabama in Huntsville (ATN-UAH) provided Tube Factory training to 12 employees. The Tube Factory simulation introduced the team to Lean Manufacturing principles and how to identify and eliminate waste, or non-value added activities. ATN-UAH worked with Available Plastics participants to observe the current process, list wastes and set goals. On the second and third days, the team redesigned the cell, implemented changes and measured the improvement.
Results:
After the kaizen event, two operators remained on the shift and operator steps decreased from 56 to 24. The distance a part traveled during the production process decreased from 45 feet to 15.6 feet. The amount of inventory in the cell was reduced by 85% from 66 pieces to ten. Floor space required was reduced 60% to 336 square feet, and production throughput improved 58% to 19 units per hour, just short of the goal.
Client Comments:
“We are always amazed at the results we are able to achieve with the help of the ATN group. They use very logical steps to simplify processes and identify waste,” said Wayne Bent, vice president of operations at Available Plastics.