Niagara Transformer Corp.

Niagara Transformer of Buffalo, NY, manufactures transformers for industry, power generation and transmission, and science and research applications. The growth of large, custom-designed transformer sales presented a production challenge for a space-constrained facility with no expansion options. TCIE launched a comprehensive Lean training program aimed at utilizing existing space more efficiently.

Solutions:

Administered Lean overview training, including an introduction to tools, and a simulation exercise for all employees
A team of 20 employees implemented 5S organizational principles and pull systems in virtually every plant area to reduce clutter and optimize the location of inventory and material supplies
Engaged employees across all levels to embrace a problem-solving mentality

Results:

Freed floor space in the plant and office by 50%
Reduced turnaround time for CAD artwork by 50% and costs by 20%
Waste reduction justified new equipment purchases to improve workflow
Reduced material replenishment time from 1 hour to 5 minutes
Added new email station to improve communications and expedite supply and raw material ordering
Improved safety of the stacking area
Standardized the design of several transformer components