Product: Cookie Cutters
Number of Employees: 14
Years in Business: 16
Location: Rutland, VT

Situation

Ann Clark Ltd. manufactures high quality cookie cutters sold in retail gift stores and produces custom shapes for corporate marketing campaigns and promotional products. The designs are the brainchild of Vermont artist Ann Clark. Her son, Ben, and daughter, Elizabeth, are the driving forces behind daily operations. They wanted to free up cash by reducing inventory and use their capacity for producing to customer demand. With intense overseas competition, they recognized the need to modify operations, so they turned to the Vermont Manufacturing Extension Center (VMEC) for assistance implementing Lean Manufacturing techniques.

Project/Solutions

Anne Clark maintains an ongoing relationship with VMEC who has provided support to the company on multiple levels. When contemplating a significant change, they contact their VMEC Professional Manufacturing Advisor to discuss pros and cons. Anne Clark is also proactive about attending VMEC workshops, and they usually send at least two employees to a workshop so they can discuss new ideas and concepts and how they may be applied to their business.

In this instance, Ben Clark and Production Manager Mike Hinchliff worked with their company team to ensure they were using all available resources to their best advantage. They rapidly implemented productivity improvements such as workstation design, standardized work, visual standards, set-up reduction, point of use storage, and some automation. Value Stream Mapping helped them see the impact that facility layout was having on their operations. The company was spread among several buildings on different floors, and the shop floor and office were completely isolated. The team analyzed options, decided how they would really like the layout to be, and then made desired adjustments in a new location. Finally, they changed their scheduling system, implemented a daily schedule of activities, and used pull systems to have strategic and controlled inventory levels.

Results

By implementing Lean manufacturing concepts, Ann Clark Ltd. has realized more than just the benefits of reduced cycle time and reduced lead times through the shop. The company now carries less than one-half the inventory they used to and they have the right product at the right time. They have virtually eliminated backorders on catalog items, which are now shipped the same day the order is received. Operators report their jobs are easier to understand and complete, and training temporary workers is simpler and faster. There are also fewer work-related injuries due to selected process automation. Most importantly, the entire company has changed its perspective on how to meet customer needs. Ben Clark has become an outspoken advocate for the power of using Lean concepts.