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For over 85 years, Flexaust has manufactured flexible hose, ducting, and accessories used in industrial and commercial applications involving air, fume, dust, and lightweight material handling.

Situation:

Flexaust was looking to increase the usage of Advanced Manufacturing tools and techniques within their production departments to increase operational efficiency. Most of their products are unique to customer specifications, so a lot of focus is on the end product and not being as cognizant of how to eliminate waste during production. They wanted to see that change from a culture not focused on rooting out waste to one that saw opportunities to eliminate waste throughout the value stream.

Solution:  

Subsidized by grant funding, Flexaust worked with Purdue MEP to develop a custom training plan focused on Advanced Manufacturing tools and techniques. Purdue MEP conducted courses including Value Stream Mapping, Problem Solving, 5S, Set-Up Reduction & Quick Changeover, and Total Productive Maintenance. In addition to the training, extra time was allocated for onsite assistance with implementation.

Results:

The trainings and implementation aimed to help Flexaust employees understand the Advanced Manufacturing tools available and enhance their mindset to root out waste. Over eight months, Purdue MEP trained 22 employees in over 120 hours of waste reduction management training and implementation techniques and tools. The cross-section of employees trained were intentionally selected to represent the entire value stream including management, production, sales, and scheduling. They accomplished their objectives and found success in many areas.

In all four main production areas, team members implemented the workplace organization method, 5S, to improve work efficiency by sorting items used and eliminating unnecessary tools that were cluttering the space. The process was well received by the operators in the department, and as a result, other production areas have requested a 5S implementation in their respective areas.

Due to the incorporation of 5S techniques on their mandrel line, production has doubled from 100 feet per shift to 200 feet per shift. With the team proving they can accommodate an increased capacity, corporate leaders have committed $120,000 in capital expenditures on new machining which will open avenues to pursue an additional line of business, therefore expanding capacity and production.

Impact metrics:

• Utilizing grant funding, Flexaust saved $22,500 in training costs
• Over eight months, completed 120 hours of Advanced Manufacturing training and onsite implementation assistance
• Trained 22 different Flexaust employees on waste reduction management implementation techniques and tools
• Production on the mandrel line has doubled from 100 feet per shift to 200 feet per shift
• Commitment to $120,000 in capital expenditures on new machining which will open up avenues to pursue an additional line of business, therefore expanding capacity and production
• Set-up times have come back down to expected timeframes – in the past the timing had been creeping up and being too long (2 hours down to 1.5 hours)
• Fostered relationships cross-departmentally – enhancing communication overall

“It has been so satisfying to see our team become involved and engaged in the process of learning Advanced Manufacturing. They are utilizing the tools we’ve learned with Purdue MEP and are finding ways to increase efficient production practices throughout the company and in many areas to implement change. These trainings will have a lasting impact on our operations and the mindset of our team. I will continue to challenge our team to make process improvement adjustments as they discover ways to improve.”

- Leigh Elliott, Operations Manager, Flexaust