Success Story: Durex Products, Inc.

Durex Products, Inc.

Profile

Location: Luck, WI
Years in Business: 42
No. of Employees: 37

Products: Highly effective, cost-efficient screening media and wear part solutions for the aggregate, mining, asphalt and concrete industries. Wire cloth, urethane and rubber screening media as well as urethane and rubber wear parts ensure greater productivity and profitability

NWMOC Projects: Lean 101, Quick Changeover, 5S Events

Situation

In the late 90s, the former company president had attempted lean initiatives without success. Early in 2007, several Durex employees attended an MOC Lean 101 seminar at Chippewa Valley Technical College in Eau Claire, and their lean journey truly began.

Project

They concentrated on 5S events first and painted their entire shop to make it cleaner and safer. A new lift table was added, and they plan to add several more. An office that was located in the center of the production floor was moved out of the production area and closer to the loom area. This move enabled them to place machines in the most productive locations to eliminate unnecessary travel and also opened up an additional 460 square feet on the production floor.   

Adding a lift table at the Press Brake improved operator ergonomics as well as eliminating 536 product movements. In October of 2007, Durex was purchased by Linatex. The safety improvements and 5S improvement ideas that were made at the Durex plant in Luck are also being done at the Linatex plant in South Africa.  

Durex Plant Manager Todd Route and Engineering Manager Chad Hackett also plan to help one of their plants in Indiana begin their lean journey in January of 2009. "They [NWMOC project managers] challenged everything and really made us think outside the box and be more open-minded," added Chad Hackett, Engineering Manager at the Durex plant.

Results

  • Increased on-time shipments from 89% to 92%
  • Increased production floor space by 460 sq. ft. (1.5%)
  • Reduced non-value-added steps (walking) by 13,126 ft/week
  • Eliminated 536 forklift movements by adding lift table
  • Sold 30,000 lbs. of scrap metal from un-needed rack that was disassembled
  • 0.3 sq. ft./hour improvement in crimping department

Before 5S Event

After 5S Event

Durex Products, Inc.

The project managers from MOC were great; they would keep asking questions until we realized what we should be looking for. It's a transformation.

~ Todd Route, Plant Manager