The Situation
TD’s mission focuses on achieving customer satisfaction through the firm’s commitment to continuous, aggressive improvement. One of TD’s fabrication goals was to increase its aggregate sheet metal production of ductwork from 30 lbs per hour to 55 lbs per hour.

A fluctuating work load, combined with current production work, had resulted in some waste in TD’s production processes with little accountability.

To achieve the firm’s new productivity goal, TD turned to its LEAN manufacturing process, used for customers, for insights and solutions.

The Solution
LEAN manufacturing is designed to drive the costs out of the manufacturing process. For the firm’s customers, TD begins by providing assigned system components to specific areas of the jobsite. This increases jobsite safety, reduces clutter, ensures on-time project completion and eliminates downtime for deliveries. By implementing LEAN manufacturing, every part of the job – people, resources, materials - is streamlined and efficient.

To tackle increased production capacity, TD implemented its LEAN principles with primary its primary focus being on 5S, 7 wastes, process improvements and leadership development. TD announced internally its goal of 55 lbs per hour and made the goal highly visible with signage, shirts and slogans. TD also identified “zones” and “zone leaders” on the production floor and placed a “status board” at each of these locations. The status boards contain the metrics and goals for the zone which are updated daily. In addition, TD implemented an early morning “gemba walk” to focus on daily schedules. The gemba walk enables management to walk the shop floor and identify ways to improve.

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