Case Study: How a Strategy Focused on Lean Manufacturing Helped an Industry Leader

Lean Manufacturing Strategy - TechSolve

Earlier this year, Cleaning Technologies Group (CTG), a global supplier of the most innovative industrial and precision cleaning technologies, faced critical challenges that required innovative solutions to meet growing market demands. Simply put, they needed to improve their efficiency – something lean manufacturing can solve – so they reached out to TechSolve for help. 

Challenge

CTG had a clear problem with a tough deadline.  “The production team operated on a 10-hour day schedule from Monday to Thursday,” explains Chris Whittaker, President of Cortex Engineered Solutions, a division within CTG.  “But we needed to double our production capability within the same work schedule and reduce our assembly time.”

This meant they had to significantly improve efficiency without compromising employee work-life balance – a daunting but critical objective.

Solution

TechSolve implemented a tailored solution  using lean manufacturing principles to help CTG overcome these challenges. Our approached focused on practical, actionable steps that delivered measurables results: 

First, we guided CTG in restructuring their assembly lines to streamline work product, enabling a 60 percent reduction in assembly time – a crucial step in achieving production goals.

We also introduced 5S principles that ensured every tool, part, and resource had a designated place, creating an organized and efficient workspace..

In addition, TechSolve facilitated  daily team huddles to improve communication and allowed departments to align on objectives, review challenges from the previous day, and establish a clear plan for the day ahead. These regular check-ins fostered better teamwork across the organization.

For eight months, one of our team members worked onsite at CTG’s Cincinnati Facility. “He felt like part of our team,” Chris expressed.  “The insights he brought from his experience that were invaluable to improving our process” 

Results

CTG’s partnership with TechSolve lead to powerful, measurable results:

  • Double production capability: CTG successfully doubled its output without extending shifts or sacrificing employee work-life balance, which led to high employee satisfaction. 
  • Significantly reduce costs:  The reduction in assembly time by 60 percent led to substantial operational savings, directly impacting the company’s bottom line and allowing for improved profit margins.
  • Enhance customer confidence: As CTG was able to maintain competitive pricing despite rising material costs, customer trust and satisfaction grew. “We demonstrated to our customers that we can meet their needs without passing on material cost increases,” Chris adds. 

The Power of Lean Manufacturing and Partnerships 

Partnering with TechSolve didn’t just help CTG overcome immediate challenges – it set the stage for sustained growth. By adopting  lean principles and focusing on continuous improvement, CTG enhanced its efficiency, strengthened its leadership position in the industry, and increased both employee and customer satisfaction. “TechSolve was pivotal in achieving our goals,” Chris says. 

What are your manufacturing goals? At TechSolve, we can help you achieve them. Contact us today to start the conversation.