Concrete Polishing Company Begins Lean Journey
About
Founded in 2004 in Norris, Tennessee, Concrete Polishing Solutions (CPS) is a privately-owned company that manufactures and distributes polished concrete floor grinders, polishing chemicals, diamond tooling, and surface prep machines for the polished concrete industry. While manufacturing is done in Norris, TN, CPS has sales and technical support representatives and distributors located throughout the United States. In addition to providing 100% hand-assembled Made in America, CPS offers a Professional Concrete Preparation Polishing and Service Training Academy. The academy is a collection of concrete grinding and polishing training courses, hosted by industry professionals and former contractors with millions of square feet of coatings & concrete polishing experience.
The Challenge
Concrete Polishing Solutions contacted the Tennessee Manufacturing Extension Partnership, part of the MEP National Network™, to inquire about assistance with lean manufacturing training and implementation activities. CPS wanted to focus on introducing their workforce to lean techniques followed up with shop floor kaizen activities. CPS’s assembly process is primarily a manual process, so the company wanted to identify opportunities to reduce cycle and lead times.
MEP's Role
TMEP helped CPS begin their lean journey by conducting an eight-hour lean overview training class for twelve associates. The training was conducted over a full day period and included a high-level overview of all the lean manufacturing tools. The training included lecture/discussion with hands on activities and gamification to help the participants experience the potential benefits in a simulated factory environment.
After completing the lean overview training, TMEP led representatives from different internal support groups in an expanded three-day value stream mapping activity. During the three days, processes were mapped, pertinent data for each process and value stream was identified and evaluated and a review of current documentation was completed. The data collected in the current state value stream map activity was further evaluated to build a strategy for improving the company's organization and support functions. TMEP continues to assist CPS in realizing the future state by facilitating internal workgroup mission statement activities derived from the value stream mapping.
RESULTS
- $2,000,000 in new or retained sales
- $25,000 in new investment
- $15,000 in cost savings