Lean Training and Implementation Helps Transform Northland Truss Systems
Northland Truss Systems
Northland Truss Systems, founded by Rick Pierce in 1992, began with a small team of truss workers, designers, a truck driver, and an office manager. Initially based in Abercrombie, ND, the company expanded to Fargo in 1993 to better serve its largest sales base, including contractors and lumberyards in the Fargo-Moorhead area. Over the years, Northland Truss has grown to become one of the largest truss manufacturers in the region, supplying projects from Grand Forks, ND to Watertown, SD, and from Bismarck, ND to Minneapolis, MN. Northland Truss continued to innovate, purchasing new equipment and expanding their plant to increase productivity. Northland Truss Systems is known for its commitment to quality, reliability, and customer service. They provide a range of products, including roof and floor trusses, microlams, I-joist hangers, and structural posts and columns. Their mission is to exceed customer expectations in pride, quality, reliability, service, and creativity.
Northland Truss Systems faced several challenges that led them to attend Lean training. Initially, they experienced significant communication issues and high employee turnover, often struggling to maintain a full roster and running shifts with insufficient staff. These problems were compounded by communication roadblocks between their two sites.
Impact Dakota provided Northland Truss Systems with a comprehensive perspective on their operational challenges and areas for improvement. They conducted a thorough Business Excellence Assessment, which highlighted significant communication issues and high employee turnover. This assessment helped Northland Truss identify specific areas needing attention, such as enhancing internal communication, improving employee engagement, and optimizing production processes.
Impact Dakota's recommendations included implementing huddle boards to facilitate better communication among staff, establishing a rewards and recognition program, organizing company events to boost morale, and improving employee benefits and pay scales. They also suggested running a shuttle bus service to attract employees from Wahpeton to the Abercrombie site.
Additionally, Impact Dakota provided Lean 101 training to Northland Truss team members, which helped them improve their production processes and layout their new assembly line more effectively. This training, combined with the other improvements, led to a significant enhancement in company culture, employee engagement, and retention.
Training three employees in Lean 101 and one in Lean Enterprise High Performance Management (LEHPM) had a significant impact on Northland Truss Systems. The training led to increased productivity by streamlining their production processes and reducing waste. This efficiency boost translated into higher sales, as they could meet customer demands more effectively and take on additional projects. The improvements also attracted new investments, allowing Northland Truss to expand their plant and purchase new equipment, further enhancing their capabilities. Additionally, the cost savings from reduced waste and improved processes contributed to a healthier bottom line, enabling the company to reinvest in their operations and workforce.
One of the key changes implemented was a straight-line process for assembly through their building. They integrated their new automated linear saw, acquired through the Automate ND funded by the North Dakota Development Fund (NDFF), directly into the truss assembly line. This setup, along with the addition of point-of-use (POU) supermarkets for truss hardware, significantly improved workflow efficiency and increased production time by 20%. Northland Truss is still waiting for the full system jigging and laser system, which will further enhance their production capabilities once installed.
"Partnering with Impact Dakota has been transformative for Northland Truss Systems. Their BizX and Lean training programs, along with the support from the AutomateND award, have significantly enhanced our productivity and efficiency. The implementation of a straight-line assembly process and the integration of our new saw into the truss assembly line have streamlined our operations. We are particularly excited about the upcoming full system jigging and laser system, which will further elevate our capabilities. Impact Dakota's expertise and guidance have been invaluable in driving our growth and success."
— Chris Lange, President