Since 1957 Davis Interiors has been well known for their quality, integrity, dependability, and consistency of workmanship in providing habitability solutions for the Marine, Commercial, and Residential markets.  Davis’ capabilities include design, fabrication shop, paint shop, sewing room, upholstery shop, lamination shop,  and quality assurance.  Davis has approximately 35 employees and is located in Norfolk, Virginia.  This location serves them well as it is in a region known as the heart of shipbuilding and marine repair.  Davis is a small business that is “Woman owned and operated”.

Situation:

Since 2003 the Virginia Applied Technology & Professional Development Center (VATPDC) has managed the integration of a Lean Supply Chain Management (LSCM) project in the Hampton Roads region of Virginia.  This program involves working with a select group of suppliers, identified by Northrop Grumman Shipbuilding as being strategic to their on-going success, implementing Lean concepts.  Being one of these key suppliers, Davis Interiors was selected to participate in the program.  Davis quickly realized the potential benefits available to them by embracing the Lean concepts and methodology as defined by the LSCM project.

Response:

Initially, this Lean Implementation Project involved an assessment conducted by VATPDC to determine the knowledge and level of application of Lean practices currently realized within the Davis environment. This assessment helped to identify improvement opportunities to implement Lean practices so as to close the gap between current and desired performance levels.  Next a Lean implementation team and a Lean Champion were identified, from within the Davis organization, to participate in the change efforts. This group was exposed to training, conducted by VATPDC, consisting of Lean Principles and Value Stream Mapping (VSM). 

At this point the decision was made to focus this project on the Fabrication shop portion of the Davis business.  Subsequently, VSM activities were completed and an implementation plan was developed entailing efforts like; workplace rearrangement, facility upgrades, 5S activity, safety program enhancements, work sequencing, and visual management techniques. 

Initial results of the implementation team’s efforts were so dramatic that Davis decided to continue on the Lean journey and become a Certified Lean Enterprise.  This certification is provided by VATPDC to companies that realize a level of performance in the application of Lean tools to a pre-established standard.   Thus, Phase two began.

This second phase addressed the remainder of the Davis business and focused on improvement activities like; streamlined quoting procedure, standardized work, work sequencing, visual inventory/warehouse management and storage techniques, 5S activity, and a new material procurement procedure.

As a result of this two phase activity to become a Certified Lean Enterprise, more than 47 unique action items were identified and implemented at Davis.

Results:

In March of 2008 Davis Interiors was recognized by VATPDC as having achieved the requirements necessary, and was awarded the “Certified Lean Enterprise” status. Fundamental business activities such as quoting, inventory control, shipping & receiving, shop order release, work flow sequencing, material procurement, and general facility appearance have reached a point never before realized within the Davis Interiors organization.  Workers received performance bonuses based on quality and customer satisfaction goals being realized.  Business opportunities continue to grow while quality and delivery performance metrics continue to set all-time “best performance” levels.

Testimonial:

“Implementation of Lean has so fundamentally changed my business, for the better, that I openly encourage everyone to embrace it!” Rexanne Metzger President and owner of Davis Interiors

“At first I was a little skeptical of Lean.   I really thought we were doing a good job of running our business.  However, Lean has had a very positive effect on the way I now view change and basic business practices.  I now have more time to focus on business issues”. Ron Brown, Plant Manager

“The Lean program helped me define my role with Davis Interiors and acquire better organizational skills.  Working with Lean has streamlined Davis Interiors to make it remarkably safer, cleaner, and a much more efficient work environment”.  Angela Wallace…Implementation Team member

“The Lean Program has greatly improved the efficiency in:

                Purchasing - The Purchase Requisition form eliminates several interruptions during the day and/or trying to remember verbal requests to order something.

                Inventory Control - Everyone is more conscious of recording items removed from inventory for job usage; therefore, better inventory control and accuracy! 

               Receiving - When a shipment comes is, either myself or one of the warehouse personnel receives the item, removes the packing slip so that I can immediately record the item as being received, get it tagged for proper identification & put on the job rack or put with inventory items.

 The Lean Program has made my job easier and the general work flow smoother”!  Esther Schumaker…Implementation Team member