Multiple Programs Dramatically Improve Manufacturer’s Operations

BACKGROUND:

Assured Automation is a leading provider of automated valves and flow components for industrial process control applications. For over 20 years the company has been providing state of the art automation to a diverse clientele ranging from small equipment manufacturers to the Fortune 500 Manufacturing, Chemical and Pharmaceutical companies. The Clark NJ company employs approximately 25 people who work to distribute values and actuators that meet ARRA-American Recovery and Reinvestment Act requirements. Beginning in 2003 Assured Automation and NJMEP have partnered on multiple programs to improve the company’s assembly and workflow processes.

With NJMEP’s assistance, Assured Automation implemented a Lean “Train-Plan-Do” Pilot program, where its employees gained a strong understanding of the type of production processes best suited to its products and the needs of its customers. When Assured Automation wanted to attain ISO 9001:2008 registration to expand its client base it turned to NJMEP to train its personnel.

SOLUTION:

Most recently the company wanted to improve customer service levels, reduce inventory, and decrease lead times. Again the company turned to NJMEP.

To identify the best approach to meet Assured Automation’s objectives NJMEP conducted a no cost assessment of the company’s processes, analyzed the results and then designed a plan that would accommodate the company’s production schedule. Since the company was an excellent candidate to apply for a Skill4Jersey grant to help defray training costs NJMEP assisted in the application for the funding. Once approved, a schedule was set up and the plan was implemented to train the employees.

Over a course of one year, five training sessions were conducted. William Farrell, President of Assured Automation explained the program, “During the project, we focused on Value Stream Mapping, Total Productive Maintenance, Set-up Reduction and Cellular Flow Manufacturing.”

RESULTS:

Assured Automation met its objectives—improved customer service levels, reduced its inventory and decreased lead times which resulted in:

• Increased sales: $50,000
• Created 2 positions in sales and 1 in marketing
• Achieved a cost savings of $50,000
• Investments in new products and processes: $25,000
• Invested $36,168 in workforce training and
• Saved $24,000 as result of the Skill4Jersey Training grant

Mr. Farrell added, “This training contributed to our sales growth and allowed us to create three positions. The Lean training has helped us tremendously. Thank you NJMEP for assisting us through the grant process and providing us with excellent instructors.”

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