“We were thrilled with the support from IMEC. The Six Sigma Green Belt training has empowered our team to identify and eliminate inefficiencies, leading to significant cost savings and improved operational efficiency. This training has been a game-changer for our continuous improvement efforts.”Karen StevensController - Rutland
Situation
Founded in 1883, Rutland became a leading manufacturer of products for fireplace, chimney, and stove maintenance. Over the last 140+ years, Rutland grew from a small family-owned business in Rutland, Vermont, to an industry-leading manufacturer. Their headquarters and manufacturing facilities are in Jacksonville, Illinois. Rutland products are available nationwide at leading retailers including Ace Hardware, Amazon, Home Depot, Tractor Supply Company, along with locally-owned stove, grill, and hearth stores.
Rutland is a small manufacturer and had no formal continuous improvement processes. The company identified an opportunity to provide Six Sigma Green Belt training for key members of their team in order to foster a culture of continuous improvement. The company wanted to upgrade participants’ skill sets, to enable them to identify production waste, cut unnecessary product costs, and improve profitability. The ultimate goal was to develop a strong team of continuous improvement leaders. Rutland would benefit from these leaders’ new skills by remaining competitive, retaining employees, and growing their business.
IMEC Solution
Recognizing the need for a structured approach to continuous improvement, Rutland contacted IMEC to help provide specialized Six Sigma Green Belt training. This training, which utilizes the DMAIC (Define-Measure-Analyze-Improve-Control) problem-solving process, results in significant cost savings by reducing waste and improving processes and productivity.
The IMEC team soon got to work and coordinated a nine-day schedule that consisted of a train and do process. Participants learned skills that they then applied to actual problems they were experiencing in the facility. Laura Lee Rose, a Six Sigma expert who previously worked with both IMEC and Missouri Enterprise, provided the instruction and mentoring for all the Rutland participants.
The Six Sigma Green Belt Training significantly benefited Rutland by improving their manufacturing processes andidentifying cost-saving opportunities. The training led to:
- Enhanced operational efficiency
- Identification and elimination of unprofitable products
- Potential cost savings through improved material sourcing
- Overall improvement in profitability and competitiveness
Impacts
- Aggregate Impacts: $367,813
- New Sales: $175,000
- Total Cost Savings: $8,000
