Voltaix Turns to NJMEP’s Lean Manufacturing to Improve Business
Voltaix is a North Branch, New Jersey manufacturer of high purity
specialty gases and chemicals for emerging applications related
primarily to electronic and photonic devices. Founded in 1986 by John
de Neufville, Ph.D., the company has developed proprietary gas
manufacturing capabilities and an array of products that are used in
chemical vapor deposition (CVD) and ion implantation processes to
enhance the performance of silicon-based semiconductor devices such as
computer chips and solar cells.
The rapidly growing company has over 40 employees. Voltaix develops new
products through collaboration with customers, and sells them either
directly or through major international electronic gas distributors.
Voltaix and NJMEP were introduced through Raritan Valley Community
College, an NJMEP partner, when the company was seeking assistance in
the areas of process and continuous improvement. The project began in
January 2005 with an Introduction to Lean Manufacturing Workshop with
simulation, led by NJMEP. An on-site Lean 101 program was undertaken
next, followed by a 5S kaizen event led by third-party resource MRC
(Manufacturer’s Resource Center).
During the improvement project’s two-month duration, approximately 25
Voltaix employees participated in various capacities. NJMEP field
agents provided Lean Manufacturing education and worked with RVCC
(Raritan Valley Community College) to write Lean programs into the
company’s grant. The field agents also worked with Voltaix on
scheduling and logistics concerns; delivered the Lean 101 Workshop;
qualified MRC and co-piloted the 5S program with them; and introduced
MRC at the 5S kickoff. NJMEP also monitored MRC’s effectiveness during
the project, which concluded in March 2005.
Voltaix expects that the 5S program, when fully implemented, will
enable the company to achieve several important goals, including
reducing inventory levels; significantly improving workplace
organization; increasing workplace safety; and elevating the level of
customer service and throughput. Anticipated cost savings and sales
growth are in the $100k range for the first stage.
The next step will be the full implementation of 5S. Voltaix plans to
continue working toward ongoing improvement and a Lean environment.
“The training provides our employees with a tool kit that will help our
continuous improvement teams improve quality and reduce lead times,”
assessed Matthew D. Stephens, PhD., Voltaix’s Chief Operating Officer.
“To our customers,” he continued, “this means improved responsiveness.
Further, Lean Manufacturing techniques lead to streamlined processes
which are safer to operate,” Dr. Stephens concluded.
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