Success Stories

MEP Member

Florida Manufacturing Extension Partnership

Story Title

Baron Sign Manufacturing Wins Big with Lean

Client Profile

Baron Sign designs and builds custom interior, exterior and wayfinding signage for residential developments, commercial projects and institutional markets including airports, hospitals, hotels, marinas, municipalities, developers and financial institutions. In operation since 1983, Baron employs 50 people at its facility in Riviera Beach, Florida.

Situation

Baron was experiencing a strong growth pattern that is expected to continue for the next several years. The owners realized that they could no longer operate like they did when they were a small company. Systems had to be implemented and the company needed to Lean its operations in order to remain competitive. Current administrative practices and disruptions in information flow were creating waste of time and resources, resulting in lost productivity. Lack of accurate controls over production processes and cycle time were causing inefficiency in machine and personnel utilization. Baron Sign contacted the Florida Manufacturing Extension Partnership (Florida MEP) for assistance.

Solution

Florida MEP reviewed current processes at Baron Sign and recommended a Lean Transformation Training program which would meet Baron’s main objectives. Florida MEP provided training for the company on the principles of Lean Manufacturing and conducted Value Stream Mapping and Kaizen events in the administration and shop areas. With Florida MEP’s assistance, Baron Sign streamlined its order entry process, increased cash flow through process improvement, recaptured plant space by organizing floor allocation to various departments, and eliminated non-performing producing lines to increase capacity for core products.

Results

• Increased sales by $500,000.
• Retained sales of $250,000.
• Realized $50,000 in cost savings in labor, materials and overhead.
• Recaptured 10 percent of plant space.
• Created 6 new jobs.
• Retained 10 jobs.

Testimonial

“We got great value from working with the Florida MEP team of professionals who were able to show us lost space, lost time and lost productivity in our own shop. Additionally, funding and staffing assistance from Workforce Alliance allowed us to complete this training and identify new qualified people to bring aboard Baron Sign Manufacturing.”
Sandra Foland, President