Ohio Manufacturing Extension Partnership
Process Improvement Transforms Global Market Competitiveness
Amano Cincinnati creates parking, time, security, and access systems that are used in commercial and government markets throughout the world. Employing approximately 90 people at its Loveland, Ohio manufacturing facility, Amano Cincinnati has been delivering innovative technology solutions for over 40 years.
Amano Cincinnati had to increase its space, workforce, and output after consolidating with an Anaheim, California Amano plant. The company faced increasing backlog on the pay station line and needed to find a way to raise its production. Amano Cincinnati saw this as a continuation of their past process improvement work with TechSolve, a NIST MEP network affiliate, and they teamed with them again to boost production and build employee capabilities.
The Amano / TechSolve team first analyzed the current pay station line. They investigated and documented the assembly process, including workflow and tooling and equipment needs. Improvement events were held, empowering those closest to the process, the operators, to uncover and solve problems. Discovering the limitations of their current process, Amano Cincinnati evolved the layout of the pay station assembly area from a system of subassemblies that fed into a final assembly station, to a new assembly sequence with each operator building from where the previous station left off. In order to sustain the improvements made to the production line, Amano Cincinnati operators were trained on the new assembly work station. A staffing matrix was also developed to meet multiple demand levels, balancing the operations to meet customer demand. TechSolve’s assistance has led to to the retention of several jobs, an increase in inventory turns, and a reduction in required floor space, freeing up area for other production lines.
- Increased sales by $1 million.
- Produce 24-30 units per month.
- Reduced lead times by 50 percent.
- Achieved a more competitive and profitable position.
“It was a very successful Kaizen event with instantaneous results. We have transformed pay station assembly and have improved our response to the customer. It is a win-win.”
Kash Gokli, Vice President, Manufacturing