OMNOVA’s Road to Lean Leads to Increased Finished Goods, Reduced Work-in-Process,
Reduced Inventory
“To be successful in the marketplace as a small volume manufacturer,
we must have a customer focus. The MassMEP’s lean training is
helping us turn this into a competitive advantage. Our road to lean
is only beginning. There are many steps we must take to continually
improve facility performance, but a solid foundation has been put
in place.” – Wesley Reid, Director of Operations, OMNOVA
OMNOVA, Performance Chemicals Division, Fitchburg, Massachusetts, produces
customized emulsion polymers using several specialty chemical applications,
such as nonwovens, textiles, construction, floor care, and graphic arts.
Situation
OMNOVA wanted to improve its production process to make a positive
impact on quality, cost, and on-time delivery. At the same time, they
wanted to maximize utilization of current resources, people, and equipment
at this facility. The company hoped to achieve this goal by instituting
simple, standardized production processes that increase the company’s
customer-service flexibility.
Solution
OMNOVA engaged in a MassMEP lean implementation program featuring continuous
improvement methods in targeted production areas. The process began
with a Lean 101 seminar to teach the OMNOVA the basics of lean philosophy
and implementation. Then a Value Stream Mapping exercise illustrated
the present state of operations and identified areas of improvement.
OMNOVA used this learning to create improved conditions throughout the
value stream, creating a foundation for continuous improvement in other
production areas.
MassMEP then conducted a Kaizen blitz focused on the 5S office organization
principle. OMNOVA also redefined utilization of its raw materials storage
space through an internal/external Kanban program. The plan provided
much needed space for staging of packaged outgoing products while providing
a systematic replenishment system with a key raw material supplier.
This activity created better utilization of cash reserves that otherwise
would be designated for bulk raw material inventory not immediately
consumed.
OMNOVA continues to measure the impact of its training and is seeing
improved workflow, improved visibility and utilization of raw materials,
and improved utilization of cash. The company now keeps an eye toward
the future, constantly searching for opportunities to increase capacity
to meet the growing demand for its products.
