Massachusetts MEP: Massachusetts Manufacturing Extension Partnership

FOR IMMEDIATE RELEASE
February 13, 2003

For more information please contact:
Jack Healy
MassMEP
Tel: 508-831-7020
Email: jackh@massmep.org

Local Jewelry Manufacturer Learns Being Quick Means Getting Lean
Lean Manufacturing Training Increases Productivity and Eliminates Waste

ATTLEBORO, MA - When companies are looking for advertising, promotional or award jewelry they turn to EA Dion of Attleboro, Massachusetts. EA Dion has been manufacturing unique keychains, pins and awards for over 30 years and has gained a reputation for quickly delivering quality products to their distributors. This reputation has helped them build a client base that includes The Girl Scouts of America, Harley-Davidson, Mary Kay Cosmetics, Chrysler and every President since Richard Nixon.

Because distributors often come to them with requests for specialty items for company golf outings or awards presentations and the order usually comes in with a note saying "I need it yesterday," their business is one of rapid response. The team at EA Dion pride themselves on their ability to deliver exactly what the distributor wants when they want it and like any good business, they also realize there's always room for improvement.

That's why Dennis Dion, the Vice President of Operations called in the Massachusetts Manufacturing Extension Partnership (MassMEP). MassMEP helps manufacturing companies like EA Dion streamline their processes to increase workflow and decrease production time.

"It boils down to the fact that they reside in a very short lead time business, they're often required to process orders very quickly and in some cases deliver finished products overnight," said David Hess, a project manager with MassMEP. "The company contacted us and asked for assistance in improving their production design and implementation, so we did a complete lean manufacturing review to see what kinds of changes should be made."

Lean Manufacturing is one of the many innovative programs MassMEP offers that helps drastically reduce manufacturing cycle time, improves on-time shipments, reduces work in process, improves quality and reduces floor space. "I was impressed with the 'get it done' attitude of MassMEP and the Lean Manufacturing concept made sense to me," said Dion. "I took two other employees to a MassMEP Buzz Electronics Lean Manufacturing simulation class and they agreed that the concept would work at our company."

Hess said he began his work with EA Dion with three goals in mind - to get a better flow of product through the manufacturing process, take delays and waste out of the system and get everyone to start thinking Lean, leading to smaller lot sizes and faster delivery.

Hess and his team conducted several Lean training sessions on the manufacturing floor that helped organize and develop a cellular flow system in the stamping, drilling and soldering areas. Working with the consultants from MassMEP, the EA Dion team has been able to make dramatic reductions in the amount of floor space taken up by work in progress, distance product has to travel from one work station to the next and a decrease in unnecessary processes.

"The changes have resulted in a 30 percent increase product throughput, better quality and lower costs," said Dion. "Training was key, and MassMEP was exceptional at helping employees understand what was going on. The transition had very few problems and I can't think of an instance where so few dollars went so far," said Dion.

Hess said MassMEP will continue working with EA Dion to improve productivity by focusing on the administrative functions of the company. "A significant amount of time is spent entering orders and we'll work with management to streamline the office functions and speed up the process even further," said Hess.

MassMEP is an affiliate of the National Institute of Standards and Technology under the U.S. Department of Commerce. The national MEP is a network of manufacturing extension centers that provide business and technical assistance to smaller manufacturers in all 50 states, the District of Columbia and Puerto Rico. Through MEP, manufacturers have access to more than 2,000 manufacturing and business "coaches" whose job is to help firms make changes that lead to greater productivity, increased profits and enhanced global competitiveness. For more information on the services Mass MEP project managers provide, contact the Worcester office at (508) 831-7020.

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