Case Studies

MassMEP is dedicated to helping our clients grow; significantly and positively impacting the manufacturing community of Massachusetts. Learn more about these growth opportunities in the case studies below.

Precisely the Right Layout for Phillips Precision

Lean Training Helps Machine Shop Expand Despite Sluggish Economy

By 2007, Phillips Precision, Inc., had reached the point that often confronts successful family-owned businesses. The machine shop, started by owners Steve and Cathy Phillips a decade earlier in a 1200 square foot garage bay, had outgrown its facility. Developing a reputation for quality work, the company attracted new clients and expanded to more than 10 employees; but space constraints began to limit not only further expansion but the efficiency of the operations.

Following a recommendation from Innercity Entrepreneurs, Phillips Precision contacted the Massachusetts Manufacturing Extension Partnership (MassMEP) to implement a Lean training program. The Lean training coincided with the company’s move to a new location in Boylston and was designed to include a plant layout for the new facility. Read More

Company Website: phillipsprecision.cc


Preserving the Progress, Davico Manufacturing Sustains Lean Improvements:
published in the "MassMEP Next Generation Manufacturing Newsletter," March 2010

12% growth in 2009

Getting their higher volume products to market faster than the competition is just one of the many positive results Davico Manufacturing reported after introducing Lean concepts at their facility in New Bedford, Massachusetts. When interviewed in June 2008, the manufacturer of direct fit catalytic converters predicted continued growth, increased sales and the addition of employees. “We would not have been able to handle this type of growth without Lean,” shared Owner and President Ray Surprenant. Read More

Company Website: www.davicomfg.com


Stabilizer FlipPad™ Manufacturer Gets Traction with ISO and Lean:
published in the "MassMEP Next Generation Manufacturing Newsletter," February 2010

The entire manufacturing process has had a 10-15% productivity improvement

A new customer, Volvo Construction, had Stoughton Steel design a stabilizer for their backhoe. They were so pleased with the design that they came from Poland to Massachusetts for a visit. Since Volvo Construction has a strict policy of using only ISO certified suppliers, Stoughton Steel researched becoming ISO certified. Andris Lagsdin, Director of Sales and Marketing for Stoughton Steel said, “I made some calls to the state (of Massachusetts) and they recommended the Massachusetts Manufacturing Extension Partnership (MassMEP) for assistance with both ISO and Lean.” Read More

Company Website: www.stoughtonsteel.com


Alexander Machine and Tool - Continues on Their Quest to Give Customers Their Best

Founded in 1969 by Stanley Stedman, the Alexander Machine and Tool (AM&T) of that time was powered by a milling machine, a turning center and Stedman’s desire to provide quality products to satisfied customers.

Today, the Woburn, Massachusetts’ company is run by Stedman’s daughter, Tammy Soper, who literally grew up with the business gaining hands-on experience at AM&T while still a student and later working her way up through quality and management positions. As AM & T’s President, Soper has focused her attention on growing new markets and working closely with clients to develop unique and creative solutions. Continuous improvement activities and Lean manufacturing concepts have figured prominently in the company’s increased sales and capabilities. All the while, quality and customer satisfaction remain a priority. Read More

Company Website: www.alexandermachine.com


Willingness to Change and Empowered Employees Help O.R.M. Succeed

"We were operating pretty successfully with the assembly line “batch mentality” when John came in and was talking about one piece flow work cells. We were astonished to see the measurable improvements from this paradigm shift." - Susan Ormondroyd

Over the years, O.R.M. Incorporated of Northborough MA has learned to diversify in order to survive. The woman-owned company was founded fifteen years ago by Susan Ormandroyd and her husband Peter and currently has nineteen employees. While manufacturing electronics is still their primary focus they also build sheet metal enclosures and provide fulfillment work, assembling kits of parts for the medical device industry. Read More

Company Website: www.ormincorporated.com


Taunton Stove's Recipe for Success

Lean followed by ISO
TASCO Engineering - a division of Taunton Stove
“The success in Shipping motivated the employees to initiate similar activities throughout the facility!” says Bruce Bodge. “People took ownership, healthy competition resulted and over the next six or eight months it (Lean) penetrated the whole shop. Employees were working on teams, and cooperating and taking pride in their work areas. Everyone seems happier,” he adds. “Doing little things to show our appreciation like buying pizza or letting the guys out a little early on a Friday really went a long way!”

From "On the Brink" to Exemplary
Recently, a group from the purchasing and engineering departments of General Dynamics in Taunton, Massachusetts toured the facility of one of their suppliers whose product quality and delivery are best in class. This event may seem un-remarkable until you consider that just two years prior, they were having difficulty doing business with this supplier. Today TASCO Engineering, a division of Taunton Stove in North Dighton, Massachusetts, is lauded as exemplary and used by General Dynamics as a success story for their Supply Chain Program. Read More

Company Website: www.tauntonstove.com


A New Perspective Helps Precision Sportswear Deliver!

“We were willing to try whatever we needed to do to lower prices, and increase turnaround time in order to be competitive and increase business."
Neal Venancio, Owner and CEO, Precision Sportswear

Situation:
After nearly thirty years in the cut and sew industry, Precision Sportswear had seen their work diminish to such an extent that they were struggling to find enough just to keep the doors open. “The passage of the North American Free Trade Agreement (NAFTA) made it advantageous to have this type of work done inexpensively overseas which caused many in our industry to close their doors,” says Neal Venancio, Precision’s owner and CEO. “We were willing to try whatever we needed to do to lower prices, and increase turnaround time in order to be competitive and increase business.“ Read More

Company Website: precspts.com


H.C. Starck - Looking Back at Two Years of Moving Forward

"A transformation has taken place at our plant as a result of the work that Mass MEP has done with H.C. Starck, Newton. I firmly believe that we would not be where we are today without the help that they provided to us."
Lee Sallade, Vice President and General Manager

Company:
H.C. Starck Inc., Headquarters of Business Unit Fabricated Products is located on Industrial Place in Newton, Massachusetts. This facility is one of twelve production sites for this international group of companies that has locations in North America, Europe and the Far East. H.C. Starck is a leader in the flexible production of engineering components made of high resistance ceramics. They work with refractory metals and advanced ceramics to develop innovative solutions for their clients and implement them into production expeditiously.

Situation:
Two years ago, H.C. Starck was early into its journey toward lean and continuous improvement. A small group of employees knew the basic concepts and had actually conducted some value stream mapping and 5s events to work on eliminating waste. They realized that there were many improvement opportunities and wanted to learn more about tools and procedures to help their company combat competition and create new opportunities. There was also the need to get all 180-site employees up to speed on these valuable tools so everyone could be involved in the process and culture change. Read More

Company Website: www.hcstarck.com


Anderson Power Products- Pull Systems Aid Uphill Climb

"The overall effect has been two-fold, not only did the process work very well, but it serves as a template and proof of concept to take the pull system to other areas of our facility." - Mark Roberts, Plant and Operations Manager, Anderson Power Products

Late in 2008, Anderson Power Products had started their Lean journey and expressed interest in working with the Massachusetts Manufacturing Extension Partnership (MASS MEP). This was prior to their current Plant and Operations Manager, Mark Roberts joining the company. Their Lean plans were put on hold, however, when the economy began to shift. This shift also resulted in a significant change in the Anderson’s workforce.

The organization began their uphill climb late in 2009 and when Mark joined them early in 2010 they were just getting back into the swing. The recovery came faster than expected and right away Roberts was tasked with finding ways to meet increasing production demands with a smaller staff while trying to re-ignite the Lean fire within the company. Read More

Company Website: www.andersonpower.com


Read more Case Studies in our MassMEP Case Studies Archive