Omaha, NE

Practice Area:
Manufacturing Systems - Lean Manufacturing Company Profile:
Signs & Shapes is a small home-owned company in Omaha, Nebraska which has grown since its start in l990 with five employees and sales under $50,000 to a staff of 21 and sales well over a million in l999. They manufacture and market Walk-Around Air-Inflated Costumes to a world-wide market.

Situation:
Signs & Shapes made the decision to move to a more technology-based production system and purchased CNC cutting equipment in early l999 with the goal of increasing its sales and indeed orders did increase. However the company was unable to respond to the demand. This involved an enormous learning curve for all employees and threw the company into a major upheaval as new computer processes were introduced. Its new automated equipment had a strangle hold on the company. There was waste on the shop floors and this disarray caused many quality problems. And the company's computer system was not Y2K compatible. This is when Nebraska Manufacturing Extension Partnership(NMEP)became involved.

Solution:
The company with help from NMEP went through a selection process to purchase additional software that could be integrated into the manufacturing software. Through the combination of new software and application of Lean Manufacturing principles Signs & Shapes was able to create a visual factory system to manage work flow and inventory, formerly a big problem. Shortages for missing raw materials stopped which eliminated the need for expensive rush deliveries to meet customers' deadlines. NMEP helped the company select a sales management software system which was also integrated into the other systems. This reduced administrative sales time allowing salesmen to sell rather than fill out reports. It also improved billing and order entry and reduced the turn-around time. By its creative linkage of off-the-shelf design, manufacturing and sales management software and an investment in high tech computer-controlled manufacturing equipment, Signs & Shapes with help from NMEP has re-engineered its operations. Every employees is computer literate and training has been both on-the-job and in off-site computer classes. Roughly 10% of the total hours worked last year has related to various kinds of technology. The staff is proud to demonstrate the various ways they use technology to do their jobs better. Because of the investment and integration of technology throughout the operation, Signs & Shapes has an eye on its future and to grow its business through Web site enhancement and 3-dimensional prototyping.

Results:
* Decreased administrative costs by 30%
* Increased manufacturing capability 25% with the same number of people
* Reduced overall lead time from point of order to shipment of product by 25%

Testimonial:
With the help of Nebraska Manufacturing Extension Partnership, Signs & Shapes has moved quickly this past year to our goal of a technology-based production system completely integrated with our other computer software programs. No more lost pieces, wasted time...we're very proud of the progress we've made this past year and thanks to our good friends at NMEP, we look to the future with great optimism.