Manufacturing Assistance Program

Lean Training and Implementation Case Study: Container Research Corporation

Company Profile

Container Research Corporation (CRC) is a leading manufacturer of specialized steel, aluminum and composite containers for shipment and long-term storage of many types of military and commercial equipment.  Three World War Two veterans founded CRC in 1956 to address the need for metal containers to replace degrading wood boxes then in use by the military and commercial businesses.  UMMAP’s engagement was with the Elkton, Maryland location which employs 20 people in a 25,000 square foot facility.  Their primary products are shipping and storage containers for helicopter rotor blades.

Situation
UMMAP was introduced to CRC through collaboration with Cecil College, located in Elkton, Maryland.  To remain competitive in today’s challenging business environment, CRC realized the need to develop a more rigorous Lean/Continuous Improvement strategy.  Through initial discussions with CRC Elkton management, UMMAP was able to prepare a Lean Transformation plan for the Elton facility.  UMMAP was contracted to deliver this Lean service to CRC Elkton.      

Solution
The initial step on CRC’s Lean journey was UMMAP’s ½ day Lean workshop to introduce Lean concepts and benefits, and discuss the applicability of Lean at CRC; three sessions were provided to educate the whole workforce.  A team consisting of CRC personnel was then formed to focus on the application of cellular assembly methods at CRC.  Additional cellular design training was provided to the team.  The team then designed a “1-piece flow” assembly process, planned and implemented the piloting of the design for one of their primary container sizes.  Adjustments were made as needed to the original design, and the cellular approach continues to be expanded and enhanced by the CRC workforce, effectively led by their Plant Manager.  In addition, improvements were made in the material supply area by working with their Pennsylvania facility.  For example, kanban systems were set up to assure replenishment of certain items. 

Results
Following are some of the benefits gained through Container Research Corporation’s Lean transformation process:

1. Floor Space / Capacity:  The pilot implementation of the 1-piece flow assembly process freed-up 50% of the floor space in the assembly area.

2. Productivity:  Implementation of the 1-piece flow assembly process and subsequent process and tooling enhancements improved productivity by 15%.

3. Material Supply:  Improvements reduced shortages by 60%.  With the implementation of the Kanban system, shortages are noticed faster and allows for corrective action to keep product delivery schedule.

4. Culture:  The workforce training facilitated improvement thinking throughout the CRC workforce.  This was evident through the Lean process and activities, but will prove invaluable as CRC continues on their Lean/Continuous Improvement journey.

Testimonial
"When CRC began the process of Lean some of our employees did not think it would work. With Dave’s teaching methods of Lean/Continuous Improvement they began to see the process and how it could benefit the assembly process. The employees of the Elkton plant have worked this process to the benefit of their jobs and increased production. (working smarter not harder). They continue to think and develop methods that help Lean to become a greater success."
-- Larry Anderson, Plant Manager, Elkton Facility

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