Leading Manufacturer of Nutritional Supplements Launches Lean Manufacturing Initiative to Slash Lead Times, Boost Sales, and Reengineer Quality
Results:
As a direct result of the MEP Lean Manufacturing projects, Albion has reduced lead time from an average of 2 weeks to same day shipping on the top 95% of their products. Customers are getting better service, orders are filled more accurately, and sales have increased 20%. Also, labor expenditures for product out the door have been reduced and the plant and the shipping areas are much cleaner and organized. Albion has received certification from NSF for their products to Dietary Supplement GMP standards, which can also be attributed to their Lean efforts.
Testimonial:
The services provided by the MEP are first rate and right on the mark. The training is simple and understandable.not so academic. Our people on the floor understand what we are trying to accomplish and as a result, they have the ability to actually implement the things they have learned in training.they are producing remarkable results. We are so pleased with our results that we have engaged the services of the MEP to assist with the implementation of Lean Manufacturing in our Iowa plant."
Testimonial Name: Earl Christiansen
Testimonial Title: Director of Manufacturing
Company:
Albion Advanced Nutrition is the world's major producer of patented amino acid chelated minerals. These minerals are used to improve the health of plants, animals, and humans. Albion's patented chelation process binds minerals such as iron, zinc, or copper, to amino acids. The results are superior absorption and utilization. Albion produces chelated minerals for three distinct markets. First, is for human consumption in pharmaceuticals, nutritional supplements, and food fortification. Second, is for animal consumption in pharmaceuticals and fortified feeds. And third is for agricultural consumption in fertilizers and plant growth nutrients. In addition to these three primary divisions, Albion offers contract manufacturing services to outside customers.
Situation:
As Director of Manufacturing, Earl Christiansen is constantly on the hunt for ways to improve his plant. He had been searching for a methodology to blue print his current processes and then apply standardized tools to improve operations. Based on a recommendation from a business associate, Earl read James Womak's book Lean Thinking. Upon completion he was convinced that he had finally identified a structured approach to implementing ongoing improvement throughout his plants. After doing additional research, he became convinced that Lean Manufacturing provided a friendly, progressive framework for improvement. It also provided a process for gaining the support and involvement of his staff.
Solution:
Earl and his plant manager attended An Introduction to Lean Manufacturing workshop that was offered by the MEP Utah. After attending, Earl and his plant manager were convinced that implementing Lean Manufacturing, Value Stream Mapping, and 5S was the key to helping them get the improvements they desired. With the help of the MEP they went on to provide training to all the plant and warehouse employees in their Clearfield, Utah. Employees continue to receive training and support for their Lean initiatives. Currently they are working on projects to improve flow, KanBan, work standardization, checks and balances, eliminating unnecessary movement, visual controls, and 5S.
Employees:
85
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