Hebron Brick’s Lean Training Fosters a Culture of Innovation and Continuous Improvement
Hebron Brick
Hebron Brick, founded in 1904 by Charles Weigel and Ferdinand Leutz, is the oldest manufacturing company in North Dakota and the only brick manufacturer in the state. The company began as the Hebron Fire and Pressed Brick Factory, utilizing high-quality clay from the Bear Den Member of the Golden Valley Formation. Initially, bricks were transported by horse and wagon, and production methods included both dry-pressed and "stiff mud" techniques. Over the years, Hebron Brick has faced numerous challenges, including market downturns during World War I and a devastating fire in 1926. Despite these setbacks, the company rebuilt and modernized, converting to gas-fired kilns and expanding its production capacity.
Today, Hebron Brick operates from its corporate office in Fargo, ND, with a manufacturing plant in Hebron, ND, and several sales and distribution centers across the Upper Midwest. The company has produced an estimated one billion bricks over its history and continues to be a leading supplier of high-quality brick products.
Their mission is to ensure that your project is completed quickly and with as few headaches as possible. They are committed to helping you complete a project that you will not only love forever but will also last forever.
Hebron Brick serves a diverse range of customers across various markets, including residential, commercial, and industrial sectors. Specializing in a diverse range of high-quality brick products, including their Authentic Americana™ collection, which features traditional, rustic styles, and Brick Lite™, a lightweight alternative to full bricks. They also offer unique Ironspots with distinctive textures and colors, Rustics with a weathered appearance, and a variety of solid color bricks. In addition to bricks, Hebron Brick provides products for fireplaces, landscaping, steel siding, and stone, catering to a wide array of construction and design needs. Their products are distributed throughout the United States; catering to homeowners, architects, contractors, and builders. The company's extensive product line, which includes traditional bricks, thin bricks, and specialty bricks, allows them to meet the needs of different construction and design projects.
Hebron Brick aims to foster a culture of innovation among its employees to stay competitive in the market. The company wants to encourages employees to see new, innovative ideas as essential for continuous improvement and long-term success. By promoting open communication, collaboration, and creative thinking, Hebron Brick wants their employees feel empowered to contribute their ideas. In addition, by adopting Lean principles and advanced automation technologies, Hebron Brick wanted to modernize their operations team, ensuring they could meet the growing demands of the market while maintaining high standards of quality and sustainability.
Hebron Brick partnered with Impact Dakota to implement Lean manufacturing in addition to their automation to promote this innovative thinking to enhance production efficiency and competitiveness. This collaboration aimed to streamline their processes, reduce waste, and improve overall productivity.
Hebron Brick's partnership with Impact Dakota has led to the introduction of Lean training programs aimed at enhancing their workforce's skills and efficiency. These programs focus on Lean manufacturing principles, automation technology, continuous improvement, and safety and quality control. By educating employees on waste reduction, process improvement, and the use of new technologies, Hebron Brick has fostered a culture of innovation and productivity. As part of this initiative, Hebron Brick sent three operators from the extruder, saw, and packaging departments to receive specialized training. This has not only improved the quality of their products but also empowered their workforce to adapt to modern manufacturing demands. Additionally, the training included a hands-on Lego simulation, which provided a practical and engaging way for employees to understand and apply Lean principles in a simulated production environment.
Hebron Brick utilized the training of three operators from the extruder, saw, and packaging departments to significantly enhance their overall training, culture, and productivity. These employees received specialized training in Lean manufacturing principles, automation technology, and continuous improvement. This training empowered them to implement several key improvements across the production process.
In the extruder area, they introduced Point of Use (POU) tools to facilitate quick changeovers, reducing downtime and increasing efficiency. For the packaging machine, they developed a system to ensure the strapping ribbon feed did not run out ahead of time, maintaining a smooth and uninterrupted packaging process. In the saw area, they implemented POU tools at each station to minimize the time spent searching for tools, thereby enhancing productivity.
Additionally, the saw area team of seven employees received training from their Lead on Lean practices, preparing them for future growth by adding additional saws. This holistic approach not only improved the quality of Hebron Brick's products but also fostered a culture of continuous improvement and innovation, ensuring the company remains competitive in the market.
"Impact Dakota's training has been beneficial for our operations. The specialized training in Lean manufacturing, automation technology, and continuous improvement has empowered our team to implement key improvements, enhancing our efficiency and productivity. This training has been especially rewarding for our long-time employees, fostering a culture of innovation and continuous improvement. We are grateful for their support and expertise."
Jerrid Soupir, VP of Manufacturing