“Identify and Reduce Waste”
Igloo said: Improve our production efficiency, and help reduce waste in the production process for a primary family of coolers.
The engineers at Scott Sheldon said: We can do that.
Igloo Products Corporation contracted with Scott Sheldon to identify and reduce waste: excess inventory, excess handling, underutilized resources, delayed visibility of quality issues.
The “Ah Ha” moment
The ah-ha moment came when we began looking at the annual cost and complexity of handling WIP: 950 miles of stretch wrap, and over 3000 miles of lift truck travel.
We knew we could do much better.
Scott Sheldon evaluated the current manufacturing process and facilitated a Kaizen Team, developed a Value Stream Map, conducted Takt Time studies for production resources, developed a connected cell layout for the components of Igloo’s highest volume product family, and entrenched a Visual Production environment
with Standard Work.
The team oversaw the transformation from batch & queue to a cellular production environment.
Breakthrough gains: variable costs reduced 17%, capacity increased 19%, WIP storage reduced 79%, finished goods storage reduced 50%, product travel reduced 94%… and stretch wrap: no longer required for WIP.
We get it.
“Scott Sheldon helped us identify tangible distribution cost savings and developed a detailed roadmap to achieve the results. With several projects now behind us, we’ve come to appreciate the ‘soft’ deliverables we get — integrity, trust and imagination — along with bottom line results.”
Vincent Rosales – Director of Distribution and Logistics, Igloo Products