TMAC Success Stories

PBV manufacturers

  • $750,000 in Cost Savings
  • $3,000,000 in increased Sales
  • Improved Efficiency
  • Improved employee engagement
  • Reduced scrap and material waste
  • PBV Valve Discovers Savings with Kaizen Events and Lean Training

PBV manufacturers and supplies an array of valves for demanding industrial applications and environments. Their advanced production, testing and inventory procedures ensure strict specification conformance, fast delivery and reliable operational performance. The 150,000 square foot facility in Houston, Texas specializes in Floating Ball Valves, Severe Service Ball Valves, Swing Style Check Valves, and custom modifications. PBV Valve is a subsidiary of Global Flow Technologies.

Situation

Fueled partially by the boom in the oil industry, PBV grew exponentially in 2007 and 2008. Growth presented challenges. To keep up with the demand, productivity and efficiency needed to be improved. Steve Twellman, Global Flow Technologies, CEO, explored options to bring in outside expertise. TMAC was contacted to see what kind of services they provided in Lean, an improvement methodology that has been proven effective for establishing dramatic results in throughput, material efficiency, and waste reduction.

Solution

TMAC Specialist David Monkiewicz and Jim Iseton met with the leadership team at PBV. After explaining the TMAC approach and illustrating the potential improvement from implementing a Lean System, an action plan was agreed upon. TMAC would conduct an onsite Principles of Lean training to teach employees how to identify time traps and waste in production. Then, TMAC would teach and facilitate a Kaizen event, a planned improvement activity that tackles a defined area or process in a facility to make it more efficient.

The training kicked off with a full day workshop. Each employee learned about the success of lean and the potential benefits to PBV. They learned specific tools that would support efficiency improvements as well as the sustainability of the impacts that would occur from the Kaizen events.

The Kaizen Team—an 8 member group led by TMAC instructors—took the training a step further. The team focused on improving material flow in the Custom Valve Department. This would be a proving ground for the concepts. If it worked, more Kaizen events would be rolled out through the company

Results

Work it did. In the 3 day event, the team improved the throughput from 2 valves per day to 12 valves per day, vastly increasing the sales capacity. This alone demonstrated that the investment was worthwhile. The cumulative impacts included:

  • $750,000 in Cost Savings
  • $3,000,000 in increased Sales
  • Improved Efficiency
  • Improved employee engagement
  • Reduced scrap and material waste

“TMAC launched the lean program at PBV and truly helped transform the company,” says Steve Twellman.“Even during the current recession and industry downturn, we continue to break revenue, backlog, and profitability records. Outstanding!” Since the training PBV has rolled out more than 10 Kaizen Events, a testament to their commitment to continuous improvement and excellence in manufacturing.

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