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Metcam completes, implements nine kaizen project

Alpharetta, Ga.-based Metcam, a fabricator of sheet metal components and assemblies for OEMs, has announced its completion of nine process improvements since it began its kaizen initiative in early 2014. Kaizen, which is Japanese for “good change,” is a business philosophy of continuous improvement through small, targeted initiatives. Thus far, the projects have netted the company as much as 30 percent improvements in throughput and reductions in cycle times to the now-modified processes while further enhancing quality.

“Through these efforts, we have reorganized and restructured production processes, inventory management, and materials planning,” said Metcam President Bruce Hagenau. “Among their many benefits, the kaizens have allowed us to integrate quality assurance more intentionally and thoroughly into our production processes―and to reduce our dependence on overtime to meet production goals.”

One of the more significant improvements was the restructuring of turret punch tool management. Punch tools previously were stored on multiple racks near each of the company’s seven turret punches, with no coordination or oversight. Tools now are organized into a dedicated tool center, with identification tags in front of each tool and an employee in charge of managing them.

Most project ideas are suggested by workers on the production floor. Of the nine changes the company has implemented, only two were overseen by consultants. The firm is considering extending the initiative to back-office processes and work flows as well.