THE CHALLENGE

With the transition to new ownership at Astra Products came a renewed commitment to improving the company's infrastructure. Astra was in a growing market, and to accept additional business, had to significantly reduce scrap and lead times and improve quality by limiting color variations in its processes. To tackle these initiatives, the Ravenna-based manufacturer of vinyl extrusion products selected MAGNET because of our ability to provide a comprehensive business solution to meet Astra's needs in these multiple functional areas.

THE APPROACH

A MAGNET team began by conducting an analysis of the company's manufacturing and business processes, concluding that Astra needed to address issues in the areas of quality, Lean manufacturing and eBusiness. MAGNET consultants then helped to assemble separate teams within Astra to address each of these initiatives. In the area of quality, an ISO team held weekly meetings to flowchart and write Standard Operating Procedures for all areas of the business to meet ISO requirements. In addition, MAGNET conducted an overview training session for the team and several supervisors from various departments to promote general awareness of ISO and its requirements.

The IT team addressed the issue of a new business system. Through an interviewing process and thorough questionnaires regarding business procedures, a MAGNET consultant narrowed the search down to several appropriate software packages. With MAGNET's guidance, the IT team then selected a new ERP business system and began training and testing.

A third team committed themselves to developing more efficient and cost effective manufacturing processes on one production line through Lean manufacturing. After experimenting with various methods of extrusion, the team refined the ink processes, added a tool cart and designed a new fan rack to help in the cooling and shaping process.

Through the implementation of Lean manufacturing, assistance on ISO implementation and ERP business system selection project, Astra has since become well positioned to enter new markets, while at the same time reducing costs and improving quality.

CUSTOMER QUOTE

"MAGNET helped us improve quality and service to our customers through a comprehensive business solution encompassing quality, shop floor and eBusiness initiatives. Because of this, we are better positioned for future growth."
Susie Smith - Customer Service/Logistic Director

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