Hero Int

Alliance for Manufacturing and Technology

Southerntier Custom Fabricators

Elmira, NY  www.stcf.com

Company Profile: Southerntier Custom Fabricators, Inc. (STCF) is a family-owned business since 1982. It employs 120 people in a 39,000-square-foot facility in Elmira, specializing in sheet metal fabrications and air-handling systems for the commercial and industrial marketplace.

Situation: STCF wanted to conduct a workplace organization program company-wide and Lean Pilot Program in its round fabrication area.

Solution: AM&T provided a customized Lean Training Program to improve workplace organization and improve productivity. It added a Lean Pilot Manufacturing initiative in round fabrication to improve profitability, productivity, business processes and expand sales.

STCF obtained a state Department of Labor Training grant and invested more than $200,000 on its own.

Over 14 months, AM&T provided a series of training events: two-hour workplace organization sessions for each area of the facility; and an eight-hour Principles of Lean Manufacturing Workshop for 16 round fabrication employees. It also provided training in Value Stream Mapping, Cellular/Flow Manufacturing and Pull/Kanban to create a cross-functional team.

AM&T included six, two-hour training sessions in Lean Implementation Planning and Project Management, and trained four key employees in basic project management.

Results: STCF...

  • Increased usable shop space 15 percent.
  • Decreased on hand inventory by 15 percent.
  • Reduced turn-around time on standard orders to 5-7 days from 7-10 days. 
  • Reduced scrap output 5 percent.
  • Increased on-time deliveries 25 percent.