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Successes in Operations

Raynor Manufacturing

Situation

In the midst of working with IMEC on an ISO 9001:2008 implementation project, Raynor was hit with a surprise courtesy of the state of Florida. To sell in Florida-an area with significant growth potential for the company-Raynor must test its products in a lab accredited to ISO 17025 standards. The company had relied on a third-party accredited lab to witness in-house testing in the past, but a change in Florida building codes now required the testing to be performed in an accredited lab, not just witnessed by one. Raynor needed to achieve the registration within three months to protect existing sales and pursue new opportunities.

IMEC Solution

Putting the original ISO 9001:2008 project on hold temporarily, IMEC and Raynor worked through the required training and documentation, prepared for the registration audit and achieved the ISO 17025 registration-all within the desired 90-day timeframe. Then, with the Florida situation resolved, the two organizations jumped back into the bigger quality improvement project and are beginning to see results in cost reduction, productivity, efficiency, quality, customer service and cross-functional cooperation.

Results

  • Successful registration to ISO 17025 standard
  • Increased market share in a significant growth market
  • Annual savings of $250,000 in third-party lab fees
  • Faster time to market

IMEC Helps Dixon Manufacturer Open The Door To New Sales Opportunities

In the midst of a straightforward quality improvement project, Dixon-based Raynor Manufacturing discovered an urgent need for specialized ISO registration-and with IMEC’s support, wound up increasing sales significantly in the process.

It all started in May 2010, when the global producer of garage doors and related products for commercial, residential and industrial consumers embarked on an ISO 9001:2008 implementation project. According to Raynor Engineering Supervisor Chris Blumhoff, the company’s goal was to build an even greater emphasis on quality through the implementation of ISO 9001:2008. Raynor’s customers don’t require the registration, but the company was looking for a proven way to enhance employee focus on customers and quality.

Blumhoff says company leaders were initially skeptical of working with an outside consultant, but after a series of informal conversations, they were intrigued by the expertise, experience and resources IMEC brought to the table.

“IMEC’s people proved they had experience working with companies like ours,” he says. “They’re not consultants who’ve studied manufacturing in a book. They’ve walked in our shoes, and they’ve had the jobs we’ve all had-production, engineering, quality. We viewed them as manufacturing peers, not just consultants.”

IMEC kicked off the ISO 9001:2008 effort with a project outline and began working with the Raynor team on implementation when the state of Florida suddenly threw a wrench in the company’s plans. To sell in Florida-an area with significant growth potential-Raynor must test its products in a lab accredited to ISO 17025 standards. The company had relied on a third-party accredited lab to witness in-house testing in the past, but a change in Florida building codes now required the testing to be performed in an accredited lab, not just witnessed by one. Raynor needed to achieve the registration within three months to protect existing sales and pursue new opportunities.

“It was practically an impossible timeframe,” Blumhoff says. “But IMEC was more than willing to jump in and help with our immediate need. They went the extra mile to bring in the resources we needed to succeed.”

Together, IMEC and Raynor worked through the required training and documentation, prepared for the registration audit and achieved the ISO 17025 registration-all within the desired 90-day timeframe. As a result, Raynor expects to increase its market share in Florida significantly. Bringing the registration testing in-house is also saving the company more than $200,000 in third-party lab fees annually. And Blumhoff says an added benefit is faster time to market, since Raynor no longer has to rely on the schedules of an outside company.

With the Florida situation resolved, IMEC and Raynor jumped back into the bigger quality improvement project, and results are beginning to emerge. Blumhoff expects the overall cost to deliver quality products to decrease significantly-a 10-15 percent reduction in year one, with exponential improvements to follow. On-time delivery has already improved to more than 98 percent, and the company anticipates significant improvements in productivity, efficiency, quality, and customer service as well.

Just as important is the impact these quality efforts are having on Raynor’s 400 employees. “We’ve already seen improvements in cross-functional participation,” Blumhoff says. “We’re moving from departments working well in silos to better communication across the organization.”

Raynor Manufacturing

400 Employees

Dixon, Illinois

“It was practically an impossible timeframe. But IMEC was more than willing to jump in and help with our immediate need. They went the extra mile to bring in the resources we needed to succeed.”

 

– Chris Blumhoff, Engineering Supervisor

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