Note: This entry is part of an ongoing series to highlight the success of NJ manufacturers!
Making growth a priority is not always easy. A delicate balance exists between survival, accepting the status quo and achieving slow sustainable growth. These three Success Stories demonstrate different aspects of growth and survival. Can your company benefit from any of these techniques used to achieve growth?
Assured Automation: Multiple Programs Dramtically Improve Manufacturer’s Operations
About The Company: Assured Automation (“Assured”) located in Clark, New Jersey is a leading provider of automated valves and flow components for industrial process control applications It employs 25 people. Over the past 20 years Assured has been supplying state-of-the-art automation equipment to chemical and pharmaceutical companies. Assured has been working with NJMEP since 2003 to improve the company’s assembly and workflow processes.
Challenges: Assured wanted to attain ISO 9001:2008 registration to expand its client base. It also wanted to improve customer service levels, reduce inventory and decrease lead times. The Company turned to NJMEP to help achieve both goals. Assured assessed their processes, analyzed the results and designed a plan fitting their production schedule.
Solution: NJMEP helped Assured complete an application for the Skill4Jersey grant to pay for a portion of the training costs
Results: As a result of partnering with NJMEP, Assured was able to achieve all of the goals. The reduction in lead times alone led to:
– Increased sales of $50,000
– Achieved cost savings of $50,000
– Investments in new products and processes: $25,000
– Invested $36,168 in workforce training
– Saved $24,000 as result of the Skill4Jersey Training grant
Zodiac Aerospace: CPIM Certification and Upgraded Skills Position Company for Growth
About The Company: Zodiac Aerospace (“Zodiac” or “ZAES”) located in Wall Township, New Jersey employs 300 people locally and over 30,000 people worldwide. Zodiac provides aerospace equipment and systems for commercial, regional and business aircraft, including helicopters and space applications. Locals know the company as Zodiac Aero Evacuation Systems or ZAES for short. ZAES and NJMEP have been long time partners, tackling challenges ranging from solving manufacturing issues to providing training for the ZAES’s employees.
Challenges: Zodiac wanted to prepare one department for APICS/CPIM certification and upgrade the engineering department’s management skills. CPIM certification for the purchasing department was also another key goal. The challenge was providing ample training for each group in an efficient and effective manner.
Solutions: With the help of NJMEP, ZAES secured grant money to provide training for its employees and achieve its goals. Trainings were provided to 62 employees focusing on various Lean processes and English as a Second Language.
Results: Lead times were reduced, new sales channels were discovered and current clients were retained. Employees were also much happier. ZAES reported the following impact as a result of the training:
– Over $100,000 in New Sales:
– Over $1,000,000 in Retained Sales
– Over $50,000 in Training Cost Savings as a result of the Skills4Jersey grant
– Approximately $100,000 in additional dollars were invested in training
EarthColor: Green Supplier Network Enhances Commercial Printers Sustainability Journey
About the Company: Established in 1982, EarthColor brings highly innovative commercial printing to the market with a commitment to the environment. Since 2004, the company began quantifying and publishing its environmental sustainability efforts and performance in its annual Sustainability Report.
Challenge: The company needed to implement a comprehensive Green program encompassing every stage of the manufacturing process. It wanted to reduce the carbon footprint of every project produced for every customer. A review with recommendations was needed to point EarthColor in the right direction.
Solution: To accomplish all of its goals, EarthColor utilized the expertise of the Green Suppliers Network, U.S. Environmental Protection Agency, State Environmental Experts, Original Equipment Manufacturers, Suppliers and of course the New Jersey Department of Commerce’s Manufacturing Extension Partnership (NJMEP).
Results: EarthColor achieved significant cost savings and established a plan for continuous improvement. The company’s NIST survey, which was completed nine months after the project was completed, reported the following success from the project:
– New or Retained sales of $3,000,000
– Cost savings of $500,000
– Investments in new products and/or processes of $200,000
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