Cultural Program
Continuous Improvement.
Our CI program turns shop-floor observations into implemented changes. Below: four real examples from the SPM floor — each documented as a Problem and a Solution.
The Program
Documented examples, not slogans.
Continuous Improvement at SPM is a documented program, not a slogan. Our Quality team encourages every employee to identify Opportunities for Improvement (OPIs), document the problem, and propose a solution. When solutions are implemented, we track the operational impact. The four case studies below are recent examples: each one started as a problem someone on the floor noticed, and ended as a documented change to how we work.
Recent Case Studies
From shop-floor observation to implemented change.
ERP Barcode Scanners
The Problem:
Our ERP system documents all of the processes occurring on the manufacturing floor, but it needs to be updated in real-time or downstream processes will slow. The powder coat line is dynamic and always in motion, so team members did not have the time to manually log the completion of every work order as soon as they finished them.
The Solution:
When the pieces of a work order are hung on the line, special tag pieces are hung in front of and behind the work order. These tag pieces have a barcode that corresponds to that work order in our ERP. A barcode scanner is positioned in front of the paint booths so that the tags are scanned as they pass by. This information allows our system to track how much time passes between the first and last pieces entering the booth.
Blue LED Safety Lights
The Problem:
Employees often had trouble seeing forklifts coming, especially around corners where vision is limited. This presented a serious safety issue for the forklift driver and walking employees.
The Solution:
Blue LED safety lights were purchased and added to forklifts and angled to shine ahead of and behind them. These safety lights help employees see the forklifts from a distance and around corners, which eliminates the risk of near misses and accidents by the forklift drivers.
Powder Coat Color Pumps
The Problem:
The Powder Coat department had to clean out their powder pumps for every color, which cost extra time and money.
The Solution:
Our machining department milled tube mounts so that we can have multiple pumps dedicated to specific colors.
Engineering Review Process
The Problem:
The Engineering department did not have a way to stop the production of a part before an operation is started.
The Solution:
Our engineers created the ERP Engineering Review Process. This allows the Engineering department to add review operations to a part router.
Related Quality Programs
Across the quality system.
Operational
Lean Manufacturing
Automated systems, visual aids, and Andon systems that drive on-floor quality and reduce constraints.
Learn more →Systems
ERP System
Integrated tracking of production, inventory, customer orders, and DIR analysis across every line.
Learn more →Trust
Certifications
ISO 9001 certified company-wide. Scope-honest about what we do and don't hold.
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