Growth Manufacturers Case Study
- Flexo Concepts
- Operations
Flexo Concepts
The Challenge
Flexo Concepts was looking for a formal process to develop and introduce new products.
The Solution
MassMEP helped Flexo Concepts create a product development map and that work exposed several areas of the business that needed improvement work. Manufacturing was chosen as the first area of focus.
The development of the product roadmap identified areas of the business that were obstacles to Flexo Concepts’ ability to achieve its goals. Through Kaizen and 5S projects with MassMEP, a culture of innovation and empowerment started to emerge.
Communication was improved with daily morning meetings that review the production expectations for the day. This quick assessment provides employees an opportunity to make adjustments to schedules and address issues before they become problems.
An employee suggestion program was implemented that collects, tracks, and resolves all ideas submitted by employees. This is a real driver of the innovation culture.
Technology has been implemented that allows all product bar codes to be scanned at shipment. This information is confirmed digitally against sales orders to ensure shipments are accurate.
The Quote to Cash process now produces only a single piece of paper: the packaging list. This is done in an environment that produces 1,000s of highly configured, made to order items that are shipped globally.
The Results
20%
Capacity in Productivity Gained
20%
Increase in Jobs
The work we did with Rick and MassMEP was the catalyst for a long list of continuous improvement projects we’ve done. We have genuinely created a culture of innovation at Flexo Concepts and the work we did in manufacturing with Mass MEP was the foundation for much of the thinking and practices we use throughout the business to innovate and improve.
About Flexo Concepts
Founded in 1988, Flexo Concepts developed a process to put a beveled tip on a UHMW doctor blade to improve safety and print quality in corrugated printing.
Today, Flexo Concepts innovates and manufactures TruPoint polymer doctor blades for many markets that require roll metering or cleaning and for other specialty applications. The company does all manufacturing in Plymouth, MA, and sells almost half of its products to overseas customers.