“Most of the workflow improvements we do are prompted when we see bottlenecks or efficiency that’s not where we need it to be. By applying lean principles, our organization has significantly enhanced our workflows, reduced costs, and improved delivery and customer satisfaction.” - Paul Tillery, Production Manager for Reel Power Industrial
For over a decade, Francis Tuttle Technology Center’s Workforce and Economic Development department and Reel Power Industrial have partnered on customized workplace solutions for the manufacturer.
Located in Oklahoma City, Reel Power is a leader in the design and manufacture of winding equipment for flexible products such as cable, wire, tubing, and fiber optic materials. The machines Reel Power creates are used by companies all over the world in communications, automotive, medical, transportation, and more. The broad range of equipment includes ones that are primarily manual to others that are very highly automated.
The company provides a holistic approach to applications to deliver a complete system solution that provides more throughput and efficiencies. Reel Power's mission is to deliver innovative, lowest total life-cost, flexible material handling solutions that increase customers' profitability and lower risks.
The collaboration between Francis Tuttle and Reel Power has included multiple Kaizen events, or a Lean Six Sigma approach designed to improve an existing process. Last summer, the two organizations spent four days focusing on ways to improve the workflow within the assembly electrical department.
In the department, employees build electrical panels for the machines. Paul Tillery, Production Manager for Reel Power, said the efficiency in the department could be improved, there was no consistent workflow, and the area was cluttered.
At the start of the event, Francis Tuttle Facilitator Colin Reed met with Reel Power staff members to look at the work area and discuss desired results. Tillery emphasized the importance of making sure Reel Power’s employees from the relevant department, not just supervisors, are involved in the process as engaging employees leads to improved problem solving and innovation. By mapping out the full value stream and analyzing the current processes, Reel Power was able to eliminate waste and improve the flow from start to finish.
One change improved workflow by relocating a rack of wires and eliminating over half of the materials on the rack, storing the most-used items in the department while moving others to the warehouse.
Another adjustment was keeping fewer carts of incoming supplies in the area. Previously, there were about two months of inventory in the department at any given time. That is now down to two weeks, which Tillery said has also eliminated inventory getting lost. By implementing new pull systems, Reel Power was able to ensure production was based on current customer demands, which helped reduce excess inventory and improve efficiency.
Additionally, Reel Power bought dedicated tables where electricians can build the panels, making the work more comfortable. They also provided employees with their own tools and toolboxes, which has improved organization compared to the shared approach utilized prior to the event.
“Now we have a more defined workflow,” Tillery explained. “They pull the parts from here, take them to the table, build the control panel, and put it on a cart going out. It’s made a big difference. Our efficiency is going up. Our throughput is going up. Our inventory is going down.”
Tillery said feedback from the electricians has been positive and that they love having more area to work with, better lighting, and better tools.
Earlier this month, Francis Tuttle and Reel Power completed another event for the meter department to increase workflow and decrease clutter. In the future, the company plans to focus on the mechanical side of the assembly area.
“I love when we see the need, we do it,” Tillery said. “Because our manufacturing plant is always so busy it’s hard finding time to dedicate to changing our processes and the way we work. But our team realized that it’s worth spending a few days on this because it’s going to pay off in the end.”
Tillery said collaborating with Reed and Francis Tuttle Consultant Meredith Chipman has been beneficial to Reel Power.
“Colin brings such a vast knowledge of lean manufacturing,” Tillery shared. “He’s very versatile as far as what types of improvements you want to make, whether it be layout design or improving throughput. He has that vast knowledge and can do just about any project that needs to be done.”