Lean Manufacturing: Spancretes Lean Implementation Plan and Results

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Lean Manufacturing Spancretes Lean
Implementation Plan and Results
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Henry Nagy started Spancrete as a two man block
plant in 1946 and since then it has grown into a
multi-million dollar business employing hundreds
of people. Spancrete has earned its outstanding
reputation by providing the best possible
solutions and use of precast concrete products in
the construction industry for over fifty years.
Through three generations of leadership, their
goal has been to provide excellent quality,
service and durability to their customers.
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Spancrete Divisions

• Spancrete Incorporated
• Spancrete Industries
• Spancrete Machinery
• American Concrete Pipe

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Spancrete Products

• GFRC Panels
• Risers
• Bridges
• Architectural Precast
• Beams and Columns
• Double and Triple Tees
• Spancrete Hollowcore
• Spancrete Wall Panels
• Balconies
• Stairs

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Spancrete Locations
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Results

• Increase Throughput
• 565,898 Cu.Ft. in 2003 vs. 1,134,966 Cu.Ft. in
  2004
• Decrease in DL. Hr/Cu.Ft
• .174 in 2003 vs. .162 in 2004
• Raw Material Inventory Turns
• 17.14 in 2003 vs. 25.15 in 2004
• Spancrete is a Better Place to Work

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How We Implement Lean

• Hired a Lean Coordinator
• Broke Company Down to Manageable Segments for
  Implementation (example Wet Cast Waukesha, Pipe
  Specialty Green Bay, etc.)
• Train Everyone And Retrain
• Form Core Teams Of Everyone From Executive Level
  to Plant Floor

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How We Implement Lean

• Decide What Will Be Mapped
• Collect Data
• Create Current State Map

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How We Implement Lean

• Discuss Opportunities for Improvement
• Create Future State Map
• Create Action Plan

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Barriers To Improvement

• Anxiety
• Time and Cost
• Always Putting Out Fires
• Ideas kept under our hat
• Enforcing Ideas Top Down

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Keys To Success

• Prepare and Motivate People
• Create common understanding of need to change to
  Lean
• Employee Involvement
• Trained and empowered people
• Share information and truly empowered people
• Atmosphere of experimentation
• Tolerate mistakes, patience, etc
• Willingness to take risks

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Implementation Success Factors

• Unyielding leadership
• Strategic vision based on Lean Enterprise as part
  of company strategy
• Celebrate Successes
• Celebrate Failures
• Ability to question EVERYTHING
• Deep commitment to EXCELLENCE

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Thank You