Precision Custom Coatings Goes Through a Lean Transformation

The New Jersey Manufacturing Extension Program (NJMEP) is the official representative of the MEP National Network in New Jersey. The MEP National Network is a unique public-private partnership that helps small and medium-sized manufacturers generate business results and thrive in today’s technology-driven economy. The MEP National Network comprises the National Institute of Standards and Technology’s Manufacturing Extension Partnership (NIST MEP), the 51 MEP Centers located in all 50 states and Puerto Rico.

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.

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

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.  —Mohammed Kovangji, Director of Operations

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, part of the MEP National NetworkTM. 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.

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.

Results

  • Increased sales of $1,300,000
  • Cost savings $150,000
  • Savings on Investment $50,000
  • Workforce practices investment of $99,000
  • 5 Employees retained

Could your company benefit from assistance with Lean training? Connect with your local MEP Center for more information.