Lean Transformation Secures Injection Molder’s Position as an Industry Leader
Polymer Technologies Inc. (PTI), an award winning injection molding provider, introduced Lean principles to its processes to ensure the production of high quality, sustainable and consistent product for its customers. The Clifton, NJ company, which has 60 employees, is also ISO9001:2008 and AS9100C certified. Founded in 1987 by Mel Goldenberg –CTO, PTI continues to expand and develop cutting-edge injection molding solutions under his leadership. His son, Neal Goldenberg, President, is directing the company’s innovative expertise into new markets.
The Goldenbergs wanted to grow their business and to do so they needed to streamline operations in order to reduce costs and increase inventory turnover. Polymer Technologies requested that NJMEP perform a LEAN Opportunity Assessment to identify improvement opportunities and provide an understanding of how Lean principles and concepts could be applied to their expanding business—transforming the organization to a full lean enterprise would allow PTI to reduce cost and improve competitiveness.
As a result of the assessment, Polymer Technologies and NJMEP designed a training program for its workforce that would provide them with the skills for this new manufacturing direction. NJMEP recommended applying for a New Jersey Department of Labor (NJDOL) Customized Training Grant in order to reduce the company’s training costs. Working together the application was completed and submitted. The grant would be an important ingredient in training and upgrading the skills of PTI’s workforce. The program was designed to cross train workers, giving them the skills to handle multiple job assignments. This new training would provide PTI with a much more flexible and productive workforce.
The grant was approved—NJDOL invested in PTI. Over approximately twelve (12) months, forty-two (42) frontline workers were trained in Lean principles, tools and techniques. The company transformed its manufacturing operations and processes into a competitive Lean Enterprise.
PTI’s training program significantly transformed the organization into a more profitable and competitive business.
- Improved productivity
- Reduced its manufacturing interval
- Increased on-time delivery
- Work-In Process inventory declined
- Rework was reduced resulting in a lower cost of Quality
In addition, Jim Walsh, CFO of PTI, “We’ve improved our productivity and our cost structure therefore we are more competitive. We have retained the 10 employees who were at risk and have, in fact, increased our total headcount by 3.”
When surveyed by NIST, 6-9 months after the training was complete, Mr. Walsh reported:
- $800,000 in Increased Sales
- Achieved a cost savings of $500,000
- Invested $100,000 in new products and processes
“The manufacturing organization at Polymer Technologies is always looking for ways to improve operational efficiencies. With the assistance of NJMEP we recently completed Lean training. As a result of this training we have increased the skill set of our employees and have begun to implement process improvements that will reduce cycle times, reduce operating costs, and increase quality throughput. MEP is a valuable resource to the US manufacturing community.” Jim Walsh, CFO, PTI
NJMEP’s Main Service Areas:
- Business Development Services
- Contingency and Emergency Planning
- Destination Innovation
- Energy Alliance Program
- Human Resources Solutions
- Lean Business Solutions
- Quality Management Systems & ISO
- R&D Tax Credits
- Six Sigma
- Supply Chain, Transportation and Logistics Services