Cutting the Fat, Not the Team: How LEAN Thinking Fueled PS Industries’ $34K Breakthrough
PS Industries Incorporated
Originally established in 1974 as a full-service door distributor repairing and supplying industrial doors, we had the opportunity to work with many door manufacturers and gain firsthand knowledge of what worked and what didn’t in the door industry, along with the challenges in the field that our customers faced. In the late 1970s, we began developing improved door-related products designed and manufactured specifically to excel in high draft (pressure) applications and highly abusive industrial environments. Thus, the PS Sliding Door was born. Soon after we developed an industrial Swing Door, a horizontal Sliding Roof Hatch, an Access/Inspection Hatch, our industrial air control Ventilation Louver system and much more. All these products are custom fabricated specifically to our customer’s size and design requirements. These products fall under our PS Access Solutions™ brand.
As our company continued to grow, we developed a new brand: PS Safety Access™. This product line started with our patented SafeMezz® Vertical Gate, designed to provide fall protection while allowing customers to take advantage of improved efficiency in their material handling. More safety-related products soon followed, including one of our most popular products, the Ladder Safety Gate. Currently, the PS Safety Access brand manufacturers 13 safety-related products designed and engineered to provide personnel fall protection.
In the early 1980s, we were asked to design a water-tight flood protection barrier for a lift station. We applied our knowledge of custom manufacturing and rugged design to develop our first flood barrier product, the Lift-Out Flood Barrier. We continued to manufacture custom flood barriers upon request and eventually we made the decision to develop the PS Flood Barriers™ brand. The keys to the development of this brand were innovative design, solid engineering, and high-quality manufacturing standards.
In 2023, PS Industries acquired the Flood Pro division of ILC Dover, including the Flex-Cover®, Flex-Gate® and Flex-Wall®, an innovative lineup of flood barrier products constructed using a combination of high-strength textiles and corrosion resistant hardware. These products are now manufactured by PS Industries and sold under the PS Flood Barriers brand. Overall, we offer more than 20 flood barrier products to protect facilities, critical infrastructure and assets from devastating flooding. Five of our flood barrier products, the Pedestrian Flood Door (in various configurations), the HydroDefense™ Flood Plank™, the Lift-Out Flood Barrier, the Flex-Cover Door and the Flex-Gate Side Deploy have undergone third-party testing and certification and now carry the “FM Approved” Label.
The global uncertainty of 2020 prompted the creation of PS Public Protection™, a division devoted to helping businesses maintain the benefits of in-person communication even as extra caution was needed to limit the exchange of germs and other airborne particles. These products – initially the ArmorBoss™ line of shields (commonly referred to as sneeze guards) – went to work in banks, retail stores, restaurants, reception desks and more. Today, this division has evolved to manufacturing customized doors, hatches and barriers that serve to mitigate unforeseen risks to your business or residence, both from nature and humans.
At PS Industries, our mission is to provide “products that protect people and property.” We strive to exceed the expectations of our customers, our suppliers, our competition, and our employees. The down and dirty of it is, we are innovative, honorable, knowledgeable, and excited to solve each customer’s problems.
We work with great customers every day, like NASA, the United Nations, Miller-Coors, Con Edison, Grainger, Xcel Energy, the New York City Transit Authority, and thousands of others. How do we do it? We follow the “PS Industries Way.” This guides us on every interaction with our customers, imparting a proven method for providing the correct solution to the customer’s problem or needs.
At PS Industries, Inc. (PSI), our mission is clear: to provide Products that Protect People and Property within the Effective Access Solutions Market, leveraging Custom Engineered Solutions from concept through completion with industry-proven performance. Living this mission means continuously innovating not only in our products but in the processes that support them. Recently, our leadership team embarked on a transformative journey to address a critical challenge and discovered the power of LEAN principles along the way.
The Challenge: Bridging the Workforce Gap
Like many companies, PSI faced the pressing challenge of a shrinking labor pool. As we evaluated automation options to enhance efficiency and manage workforce constraints, it became clear that we needed to lay a strong foundation first. Enter LEAN principles: a proven methodology to streamline processes, reduce waste, and maximize value.
Recognizing this, our ownership and leadership team made a strategic decision to invest in our people. Employees from various departments, including production management, scheduling, inventory management, new product design, and manufacturing engineering, were sent to LEAN training sessions facilitated by Impact Dakota. While PSI had implemented LEAN training in the past, we recognized the need for a fresh injection of energy and innovative thinking to drive real, positive change.
The Solution: Energizing the Team with LEAN Tools
The LEAN training not only equipped our team with practical tools but also inspired them to reimagine our processes. Armed with new knowledge, PSI launched a Kaizen event aimed at reducing lead times in a critical custom painting and assembly process. This effort began with value stream mapping (VSM), a visual tool that helped us define and measure our current workflow.
Using a large magnetic board located directly on the factory floor, the team mapped out each step of the process. This exercise exposed several inefficiencies, including:
- Wasted Motion: Unnecessary movement by employees during assembly.
- Long Dwell Times: Delays caused by bottlenecks in the workflow.
- Repeated Work: Rechecking and reworking items unnecessarily.
- Redundant Process Checks: Extra steps that added no value.
The team implemented several impactful changes, including designing new fixtures, altering packaging methods, and reordering workflow elements. However, the most transformative improvement came from eliminating an entire hand-fitting process. By adding CNC-located holes and locating marks upstream, we ensured precise fitment earlier in production, eliminating the need for hand-fitting checks during final assembly.
The Results: Measurable Impact and Lasting Change
The results of this Kaizen project were nothing short of remarkable:
- Annual Savings: The time saved is estimated to result in $34,000 in annual savings.
- Efficiency Gains: Workflow improvements allowed us to handle the same workload with our existing workforce.
- Health and Safety Benefits: Workers experienced reduced physical strain, thanks to the elimination of redundant tasks and ergonomic improvements.
- Cultural Shift: The energy and ideas generated through Impact Dakota's training reinvigorated the team, fostering a culture of continuous improvement.
A Step Toward Automation and Beyond
By embracing LEAN principles, PSI not only tackled immediate challenges but also set the stage for future automation. With streamlined processes and a more engaged team, we are better equipped to explore automation opportunities and further our mission of protecting people and property through effective solutions.
At PS Industries, Inc., we are proud of our journey and the resilience of our team. This success story is just one example of how investing in people and processes drives meaningful change, enabling us to deliver the high-quality products our customers rely on.
Together, we are redefining what’s possible—one Kaizen at a time.
Significant Cost Savings: The Kaizen project resulted in an estimated $34,000 in annual savings through improved efficiency and reduced lead times.
Increased Operational Efficiency: Streamlined processes allowed the company to handle its current workload with the existing workforce, mitigating the impact of labor shortages.
Enhanced Worker Health and Safety: Eliminating redundant tasks and improving workflow ergonomics reduced physical strain on employees.
Cultural Shift Toward Continuous Improvement: The training from Impact Dakota inspired a renewed focus on LEAN principles, fostering a culture of innovation and problem-solving.
"LEAN principles are more than just a set of tools—they're a mindset that empowers our team to continuously improve and innovate. Partnering with Impact Dakota reinvigorated our approach, equipping us with the skills and energy needed to tackle challenges head-on. This journey has not only streamlined our processes but has strengthened our culture of efficiency and excellence at PS Industries."
— Cory Melland, President, PS Industries Inc.