THE CHALLENGE

Thomas Steel Strip (TSS), a division of Corus Specialty Strip, specializes in electro-coating of very thin gauge steel for custom applications. As the leading supplier of nickel plated steel for battery casings for Energizer and Duracell, the company continually strives to improve their product and exceed customer expectations.

TSS realized that, in order to retain its position as a world-class leader in the industry, they needed a renewed focus on continuous improvement efforts as a way to improve the overall effectiveness and profitability of the company.  To accomplish this, the company engaged MAGNET to initiate a new enterprise-wide continuous improvement program called "Business Excellence", focusing on reducing waste in both the company’s business and manufacturing processes.

THE APPROACH

TSS began the Business Excellence Initiative in September 2004, and engaged MAGNET to provide leadership and expertise. MAGNET worked with the TSS cross-functional teams, hourly workers, management and union personnel to implement Business Excellence. At a one week boot camp, the Business Excellence Core Team focused on lean manufacturing, problem solving and statistical data analysis techniques. At the end of boot camp, the business excellence teams had one common structured method for improvement and a clear simultaneous communication of expectations.

Through MAGNET’s unique Learn-Do approach, the teams applied their new knowledge in a series of Kaizen events on both the shop floor and in the front office. Events included Quick Changeover SMED, Value Stream Mapping, Lean Office, and 5-S Workplace Organization. Significant results were obtained by  eliminating the root-causes of waste and inefficiency.

The Business Excellence Initiative is an ongoing endeavor for TSS. An internal Business Excellence Champion along with three full-time coaches were put in place to oversee and monitor this day-to-day progress and drive the initiative forward. MAGNET has become an important resource and partner for the company during this process. These results have helped TSS become a model site for corporate-level initiatives for Lean implementation within the Corus Group.

CUSTOMER QUOTE

"MAGNET had the resources, abilities and people on staff that could do what we wanted and needed. They had a proven reputation coming in and have exceeded our expectations. We believe the kind of improvements they can help our company make will have a significant impact on our business and our community."
Denny Wist - President

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