Success Story: Atlas Resin

Atlas Resin Proppants Believes Good People Are Key

logoProfile

Location: Taylor, WI
Years in Business: Since 2005
No. of Employees: 125

Products: Atlas Resin Proppants is a growing leader in the proppants industry, and leading supplier to the service segment of the oil and natural gas industry, producing many formulations of resin coated sand proppants

NWMOC Projects: Lean Training, Facilitation of Improvement Teams

Situation

Atlas Resin found it difficult to source the lean resources they were looking for—an organization with the ability, responsiveness to company schedules, and real-world experience—to provide assistance in their complex 24/7 operation.

With a strong commitment to their employees, they wanted to provide educational opportunities. Company leadership believed that people skilled in lean manufacturing strategies, as well as other skills, would allow the company to provide the highest quality products for a demanding market.

Project

NWMOC Project Managers visited their production facility to learn about their operation and what their goals were. The company wanted their employees to really understand and be able to take action with their lean manufacturing training. The NWMOC project managers suggested an approach that would begin with an 8-hour workshop providing hands-on learning of lean principles using an actual table-top production system in which the participants actually weighed product, mixed it, sent it through the "MB Processor," and finally weigh-filled the product into packages. Each new lean technique discussed was immediately tried out in the simulation factory.

To put the learning into action, a number of actual improvement events were conducted in the production and lab areas—all under the coaching and guidance of the NWMOC. The participants were immediately able to put their new knowledge into action. 

Currently, 60 people have completed this process, with nine actual production area improvements completed. The company appreciated our "Speed to Impact" model where participants actually get to practice their new skills, and the company also obtains real benefits from the projects. 

Results

  • Achieved a waste reduction of 2%
  • 60 new employees trained to understand Lean and Continuous Improvement
  • Reduced mixer cleaning time by 40 minutes per cleaning--that's 241.2 hours per tower per year! (A 30% reduction in downtime per tower)

Atlas Resin

The team from NWMOC was very professional and helped us to maintain our focus on continuous improvement with a truly team focus.

~ Cathleen Hegge, Quality and Technical Services Manager