Situation
Exodus Global reached a pivotal point in its growth. With expanding manufacturing space, new equipment, and increasing sales, the leadership team recognized the need for a structured approach to operational efficiency. They chose to implement a 5S program, beginning with their Shear Assembly shop.
Solutions
A cross-functional team of 10 employees was assembled to lead the initiative. During the Sort phase of 5S program, the team identified and removed over 70 unnecessary items, reclaiming approximately 200 square feet of valuable production space. The Set in Order phase followed, resulting in a more organized and efficient work environment.
Results
The results were both quantitative and qualitative:
- Sales increased by 8.6%, generating an additional $369,000 in revenue.
- Productivity improved by 20%, with a 50% reduction in shipping errors.
- Production time decreased by 30%, and customers experienced a 75% reduction in application time.
- Training efficiency improved, with new employees reaching 75% of performance benchmarks in just two days and 100% in six.
Beyond metrics, the initiative fostered a culture of ownership. Employees took pride in maintaining a clean and organized workspace, leading to more balanced assembly times and reduced variation. The improvements positioned Exodus Global to scale operations more effectively as demand increases.
Testimonial
“Nick provided excellent information and direction. He was personable, professional, and worked side by side with our team throughout the entire process. The hands-on approach and relevant insights have become a resource for future improvements. We’ve already replicated the success in another work center and plan to continue expanding the program.” - Michael Tezak, Director of Operations at Exodus Global