Fluortek, Inc. is an Easton, Pennsylvania-based manufacturer of custom dimensioned, extruded plastic tubing for the medical device industry. For nearly 40 years, the company has provided products in a wide range of fluoropolymer and thermoplastic materials, as well as comprehensive component assembly services.
““It wasn’t a product failure. It was a matter of how [the product] was handled and inspected. The training we received from MRC made it possible to isolate the root cause of the increase and resolve the issue. With that solution in place, the complaints all but disappeared.” … Todd Furman, Director of Operations
Fluortek, a manufacturer of precision plastic extrusions, sought to establish a Lean culture and develop consistent training across its operation. From employees advancing through the ranks to executive leadership looking to improve efficiency and productivity, the company turned to MRC for several offerings: Yellow, Green, and Black-Belt training, Supervisor Boot Camp, and the Manufacturing Leadership Institute (MLI) among them.
Solution
Fluortek’s Lean journey began with Yellow Belt Training. An MRC-led training initiative introduced several engineers and production supervisors (including the current Director of Operations, Todd Furman) to strategies that were proven to enhance efficiency and problem-solving abilities. One of the proprietary projects even led to a follow-on effort to realize further improvement.
Based on the success of the Yellow Belt project, Fluortek decided to send five more employees through Green Belt Training. In particular, the team selected a project aimed at reducing the number of customer complaints relating to a specific issue.
“It wasn’t a product failure,” says Furman. “It was a matter of how [the product] was handled and inspected. The training we received from MRC made it possible to isolate the root cause of the increase and resolve the issue. With that solution in place, the complaints all but disappeared.”
The Supervisor Boot Camp, meanwhile, was an opportunity to train all Fluortek supervisors to the same rigorous standards. Whether they were promoted to supervisory roles from within the company or came from outside, senior management realized the benefit of establishing a common level of understanding. The employees who have completed the boot camp now form a core of standardization across all departments and shifts, handling conflict and managing employees in the same ways.
The final project was MLI/Leadership training, which four different Fluortek employees took part in. These individuals, who were new to the organization or lacked leadership experience, had a chance to learn about a range of functional areas, including finance, leadership, employee management, business intelligence, and more. Much like the Supervisor Boot Camp, that training enabled the employees to have a consistent level of awareness and business philosophy.
Results
- Fluortek states that its Green and Black Belt Certification training reduced customer complaints by as much as 90% for the product at the center of their project.
For more information about Fluortek, please visit their website at www.fluortek.com.