Finding the Right Solution for SolvChem
SolvChem Custom Packaging Division is a full-service contract packager whose services include custom blending, filling and packaging of both water and solvent-based products. In an ongoing effort to deliver excellence in quality and service for their customers SolvChem called on TMAC Gulf Coast to not only locate and resolve areas of inefficiency in their operations, but also develop strategies for overall improvement and excellence.
- Improved production synchronization
- Reduced product retrieval time by 25%
- Reduced inventory management time by 30%
- Improved safety
The Situation
In order for SolvChem to meet their production, quality, and cost goals, management needed a clearer understanding of how their operation was performing. An onsite evaluation by TMAC Gulf Coast revealed that production synchronization and maintenance issues had a negative impact on productivity, quality, and safety. This led to high operational costs which were reflected in excessive overtime, delays, errors, and rework.
The Solution
TMAC Gulf Coast led management through a “Hoshin Kanri” strategic session which gave them an understanding of improvements needed and helped develop an action plan. The plan included training in Lean Principles for employees to embrace the change; reconfiguring the warehouse to improve flow and minimize product handling; devising a new labelling system to allow for quick access to product by forklift drivers, and implementing cycle counting to improve inventory management.
The Results
Working with TMAC GC allowed SolvChem to not only improve their day to day operations, but has also set the stage for long term success. As a result of TMAC assistance, production synchronization and maintenance performance have been greatly improved. Man hours were reduced by 25% for product retrieval and 30% for inventory cycle counting. Forklift congestion has been reduced and safety improved. The higher volume product is now placed closer to the shipping docks and obsolete product is consolidated and scheduled for disposal. Valuable production space was freed up. Additionally, Lean training has equipped management and employees with the tools needed for ongoing, future improvement. The most valuable result is a change in culture to self-initiated continuous improvement from the operator level up. When asked about the outcome, chief operating officer, Mark Hacas, said “TMAC Gulf Coast operated by BeehiveFund not-for profit corp. assists and guides us in transforming our company from top to bottom. Their in-depth industry knowledge, technical expertise, soft skills, and deep experience in dealing with different business cultures make them ideal partners for our complex, high-volume, high-mix production company. Through well-designed steps to transformation to Lean system, TMAC-GC provided across the board employee training and preparation, team building workshops & exercises, facility layout & technical production improvement implementation, leadership coaching, and strategic deployment exercises. All in all, their focused efforts have resulted in a remarkable set of productivity, employee morale, efficiency, and quality improvement in our company. We are happy to work with TMAC-GC and receive their continual assistance.”
