Manufacturing Assistance Program

Lean Manufacturing Case Study: Technigraphics of Maryland, Inc. (Baltimore County)

Company Profile
Technigraphics provides an extremely diverse range of custom product identification and engineered specialty graphics to OEMs across a broad range of industries. Products include membrane switch panels & keypads, front panels & graphic overlays, labels & nameplates, and related screenprinted and diecut parts. Founded in 1946, the company utilizes its broad product capabilities and engineering expertise to help customers solve problems related to design, manufacturing, application, and performance. Technigraphics products can be found on equipment in a wide variety of industries such as Telecommunications, Electronics, Medical, and Industrial Controls. Their facility is located in Hunt Valley Maryland and has 26 employees.

Situation
Due to Technigraphics_ small lot, mixed model processing environment, multiple changeovers are required in the Screen Printing Department in order to meet customer demands. Significant time was required to complete these changeovers, thus limiting available production capacity. Technigraphics and UMMAP have had previous engagements involving facility layout and Lean manufacturing assistance. The company contacted UMMAP to assist in reducing the Press changeover times.

Solution
UMMAP worked with a team of Technigraphics employees to analyze and redesign the current changeover process on one screen printing press. This project involved training and facilitating the team in the changeover improvement process during a 2-day kaizen event. The team videotaped the current process, documented and analyzed this process, and then brainstormed improvement opportunities. A new process was developed, documented, and retimed and revideotaped. As shown below, the original improvement estimate for the redesign was 53%, but the actual streamlined changeover, when retimed, demonstrated a 67% improvement.

Results

• Changeover Time Reduced from 30 minutes to 14 minutes (53%)
• Increased Available Production Capacity 50%
• Annual Savings (1 Press) $40,000
• Improved Productivity 15%
• Jobs Created: 2

Testimonial
"We have been very pleased with the products and services offered by UMMAP. They are relevant to our business and industry, and we have seen specific improvements to our productivity and profitability due to our collaboration with UMMAP."
—Trey Hooper, President, Technigraphics of Maryland, Inc.

• Success Stories
• UMMAP home page