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Operating out of a state-of-the-art 27 acre manufacturing campus, Master Spas is the largest swim spa manufacturer in the world, and one of the largest portable spa and hot tub manufacturers in the country. The company’s management team has over 100 years of spa manufacturing success, and one of the strongest track records in the industry.  Master Spas’ award winning products are available in over 300 locations in more than 30 countries.

Situation:

Master Spas was in the midst of experiencing considerable growth and needed to increase output, eliminate bottlenecks, and reduce lead times, while maintaining the high quality standards necessary to satisfy their dealers’ requirements.

Solution:

Master Spas had Purdue TAP train 20 employees on Value Stream Mapping, 5S, standard work, and quick changeover.  In addition, Purdue TAP trained 80 of Master Spas’ employees in Lean, and 14 employees obtained their Six Sigma Green Belt certification. Currently, Master Spas has Purdue onsite for two days each month for Lean consulting.

Results:

Master Spas is on a path of continuous improvement due to the training received by Purdue TAP over the past eight months.  The company has made considerable investments in factory, equipment, and employees to improve output, productivity, and employee morale.  Master Spas grew 14.5% in 2015, and expect growth of over 20% in 2016, which would not be possible without the Lean tools the company is implementing.  While the company is very happy with their outcomes, they anticipate more significant results will be realized over the next year as their initiatives and investments are completed.

“I am extremely happy with our decision to work with Purdue TAP in training our team to use Lean Six Sigma tools.  Our Purdue TAP consultant, Mike Hensley, has been an exceptional trainer and really cared about Master Spas, our employees, and the success of our Lean initiatives.  I would highly recommend the Purdue TAP program to any company that is interested in a Lean program for continuous improvement.”

-Terry Valmassoi, President, Master Spas

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