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"The training was really valuable in
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that it got people to think
about wasted effort, and how to start making changes."
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Press → Roplast
Industries |
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Roplast
Industries Oroville becomes first
Sierra College CACT Lean Demonstration Center. |
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Company transforms its operation
and now opens the door to share its success.
Roplast Industries was founded in 1990 in the foothills of
the Sierra Nevada Mountains to manufacture environmentally
friendly, high quality, low density polyethylene bags. Roplast
concentrates on fine, quality print and strong film. They
print exclusively with environmentally friendly water based
inks. They produce a wide range of bags used in numerous retail
and industrial applications. They are suppliers to well known
high end retailers such as Macy’s and Eddy Bauer and
can provide many custom features such as draw string, loop
handle and zipper bags. They also have many food packaging
industry clients and make products such as re-seal bags used
for tortillas and breathable bags used for produce.
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The Transformation |
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During
2003 Roplast Industries decided to change the way they implemented
process improvements. They where trained and mentored through
the Lean Enterprise implementation process by Total Excellence
in Manufacturing (TEiM), the Sierra College CACT’s lean
implementation partner. The results have been impressive and
the company continues to make improvements on a regular basis.
The results so far include:
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• Reduced set up times
by an average of 44%.
• Increased production capacity by 400,000 pounds
with no increase in labor costs
• A quicker response time to
clients needs
• Reduced impact of inventory
risk.
• Reduced scrap rates
• Improved
morale from a staff who now feel empowered |
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Chris Mann
the VP of Operations at Roplast characterized a Lean Enterprise
this way. “The success of a Lean Enterprise comes from
the subtle difference that, while thoroughly supported at
the senior level, the actual process improvement ideas are
first generated and then implemented where the rubber meets
the road. That is, by the staff on the production floor or
within the administrative area wherever the change needs to
take place.”
He attributed the success of the process to the fact that
they followed a plan to quickly bring all the employees up
to a level of knowledge so they would all be able to support
the changes being implemented. “By first training all
the staff, and then developing a core of additionally trained
people within Roplast, we were able to get a critical mass
of understanding and support for the process” said Chris.
Roplast is now operating as a Lean Enterprise carrying out
regular Kaizen event,s which have become the system to implement
a continuous improvement regime throughout the company.
The management at Roplast is happy to open
its doors to others to show how they have successfully implemented
lean. They know that the journey to become a Lean Enterprise
will be different for all companies and they are not giving
away secrets that will hurt them. “If California businesses
become more sustainable and profitable then all business will
prosper, and they will hopefully use Roplast products either
directly or indirectly through increased sales” said
Robert Bateman the CEO at Roplast. “We also understand
the role of the colleges, their partners, and want to be able
to give something back to the community” said Robert.
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here are members of the Roplast Core team and one of the
Kaizen teams. Kaizen
events are the system used to implement the continuous
improvement regime.
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To visit
and see the Roplast Lean Enterprise contact
Sandra Scott the CACT Director at Sierra College or for information
on how to become a Lean Enterprise Call David Jones at TEiM. |
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The purpose of the
Centers for Applied Competitive Technologies is to support the
mission of the California Community College’s Economic
and Workforce Development Program by assisting California manufacturers
to remain competitive in changing markets and a global economy.
Centers for Applied Competitive Technologies State funding for
CACT provided by the California Community Colleges Chancellor’s
Office Economic and Workforce Development program. Additional
funding assistance provided by local colleges and industry partners. |
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