Amerimax Nearly Eliminates Order Errors Using Value Stream Improvement
Amerimax Building Products is a national manufacturing company headquartered in Texas with 15 locations across the nation. The Amerimax Loveland facility’s 55 employees produce and distribute high quality, energy efficient, custom residential vinyl windows and doors as well as provide administrative and customer service for two window manufacturing facilities. Part of the Loveland community for over 40 years, they have been producing windows and doors for the past 25 years with consistent growth.
Both internal and external customer service are key components to Amerimax’s success, which includes achieving tight deadlines, on-time product delivery, and increased focus on customer service with faster and more accurate order entry processing. Meeting a CAMT representative at a Business Fair sponsored by the Colorado Office of Economic Development, Neal Bretting, Sourcing Manager, asked CAMT to help enhance office operations. CAMT and Amerimax are conducting a series of Value Stream Improvement (VSI) projects to identify the critical process areas needing change to increase efficiency, accuracy and customer satisfaction.
The first VSI included the participation of the entire office staff and focused primarily on the order entry & customer service process. First, the staff documented every step taken in the order process, asking who, what, when, why and where of each step. They recorded the time needed to complete each step, the motion (walking distance) required, and then analyzed all details. Actions stemming from the VSI included eliminating non-value added tasks, leveling staff entry order volume, rearranging the office to streamline efforts and walking steps needed-- including the elimination of one third of all cubicle walls--, and the updating and creation of comprehensive Standard Operation Procedures.
By defining and mapping the most efficient process, Amerimax has improved the ordering process, while helping to eliminate customer order entry errors. With the help of VSI, the order entry process accuracy has improved 38% in reducing total order process times. In addition, the customer order confirmation process has improved nearly 70%, from 28 hours to 12 hours.
“Operational excellence, business development and employee development are our 3 Pillars for Success. The VSI program involved all 3 areas! A key goal is ensuring all staff is committed to continuous improvement, to offer the best customer service and value. CAMT’s VSI engaged all employees, making them integral with ownership to the improved process changes and our success into the future.” - Neal Bretting, Sourcing Manager.
Results:
- Cost Savings: $50,000
- Retained Employees: 1
- Created Employees: 1