Issue link: http://cp.revolio.com/i/281113
a scrap rate of 13% of all the EPS they produced. In the interest of reducing costs, Progressive Foam used a variety of resin. As a result the parameters of the molding process were constantly fluctuating, resulting in lower-quality products. Once they decided to reevaluate their practices, it was clear the first step was to start with a consistent, high quality resin. A bag-by-bag analysis of every resin shipment was implemented to screen for particle size. Each evaluation contributes information to a database of every resin shipment they receive. That data is then evaluated through a process pioneered by Progressive Foam called "correlation analysis" and used to adjust pre-expansion parameters to compensate for variations in resin. Further data is acquired by networking their expansion and molding machinery to feed information back to their central database. Once analyzed this information allows for fine tuning of the resin particle size and foam density relationship during the molding process to create the best possible foam. It took about a year before enough data was acquired to make accurate adjustments, but now using Six Sigma tools, Progressive Foam created an Individual Moving Range Chart that allows them to detect changes in the expansion and molding process that they may or may not want and adjust accordingly. They have also limited their resin suppliers to only two in any given year. This may seem complicated, but the basics are a simple matter of tracking data. Plasti-Fab has implemented a similar program that tracks yield numbers, and allows adjustments to be made when the numbers deviate to maintain efficient production. "People often think that process control is over their head and they give up. In reality you can't afford not to do it," says Pat Culpepper, President and CEO of Progressive Foam. Culpepper says that full process control from start to finish can be instituted within two years. The human element is always a variable when striving for the utmost efficiency and quality, but possible human error can be mitigated by making sure employees are regularly educated and trained. Plant workers are a vital part of Progressive's Man-Machine-Material system (based off of the Ishikawa diagrams). Machine operators are required to be certified on any equipment necessary for their job, many workers hold multiple certifications, and refresher training is offered annually. The combination of quality resin, data acquisition, and worker training has allowed Progressive Foam to provide a better product. Despite the fact that their sales were 43% higher before optimizing their production, they have shown higher profits and have not received a warranty claim in 3 years-proof positive that their efforts have paid off in more ways than one. Scrap Foam Scrap foam can be a large source of waste for companies, and a missed opportunity for additional revenue if not handled properly. Progressive Foam cites their biggest success as reducing the amount of scrap EPS they produce. "I can't think of anything that is more important to creating a sustainable business than scrap reduction," says Culpepper. Prior to re-evaluating their manufacturing efficiency, Progressive Foam was sending seven dumpsters of scrap foam to the landfill from each of their plants per week. Now, thanks to their improved quality control methods and a proper utilization of sellable scrap, they send only one dumpster a month and boast a 1% waste scrap rate. Most scrap foam in an EPS manufacturing facility is produced during cutting, but the amount of scrap made this way can be reduced by getting as much usable material from each block as possible. From each block of EPS they make, Progressive Foam cuts 3 - 4 different commodities. Waste layers are then used to produce other sellable product like corner posts, window lineal or shim, which is used in the installation of insulated cladding products. Whatever is left over is collected to be sent to other companies and recycled into other products. There are many companies that rely on scrap EPS as a raw material to produce their products. When all things are considered (utilities to produce, labor, etc.) scrap EPS is 2 continued from cover People often think that process control is over their head and they give up. In reality you can't afford not to do it. – Pat Culpepper, President and CEO of Progressive Foam