Situation
Exodus Global, a leading manufacturer of mobile shears and attachments based in Superior, Wisconsin, found itself at a critical juncture in its growth. With expanding manufacturing space, new equipment, and rising sales, the company recognized the need to improve workflow efficiency and enhance workforce education. To address these challenges, Exodus Global partnered with the UW-Stout Manufacturing Outreach Center (MOC) to implement a Value Stream Mapping (VSM) initiative.
Solutions
Rather than tackling the entire organization at once, Exodus Global and MOC facilitators Nick Ford and Matt Wakefield focused on a specific area of operations. A cross-functional team was assembled to participate in the VSM process. Together, they physically mapped and walked through each step of the workflow to identify inefficiencies and sources of waste. Once these areas were pinpointed, the team worked collaboratively to reduce or eliminate them. Encouraged by the success of this initial effort, the company expanded the process to two additional areas.
Results
The VSM initiative delivered significant improvements across multiple dimensions:
- Productivity: An 80% improvement in information processing time.
- Culture: A more safety-conscious environment was fostered through the purchase and installation of ergonomic lifting equipment.
- Efficiency: Order fulfillment time was reduced by 67%.
- Sales: The company achieved a 95% success rate in 24-hour shipping for service and replacement parts, contributing to increased and retained sales.
Testimonial
“The MOC facilitators (Nick Ford and Matt Wakefield) provided excellent information and direction. They were very personable and professional, working side by side with our team both in the classroom and on the floor. Their hands-on guidance meant a lot to the team and made the process more impactful. The information provided was directly applicable to our business and will serve as a valuable resource for future improvements.” - Michael Tezak, Director of Operations at Exodus Global