Automation Leads to Increased Efficiencies and Sales

THE CHALLENGE

A-1 Industries has been seeing year-over-year growth, leading to increasing its market share for their products and services. The company faces challenges with the rising cost of raw materials, offsetting these rising costs through more efficient and safe operations, and finding and securing qualified people to employ. The management team at A-1 Industries reached out to the South Florida Manufacturers Association (SFMA), part of the FloridaMakes Network and the MEP National Network™, to help identify areas of opportunity for improvement.

FLORIDAMAKES ROLE

A-1 Industries is a member of the South Florida Manufacturers Association and was nominated to participate in the SFMA’s Manufacturer of the Year Awards process in 2022.  The company won the award for its group and received a written feedback assessment that detailed areas of opportunity, which included recommendations from the local FloridaMakes Business Advisor on the implementation of automation in several areas of the company that would help to improve operational efficiencies and reduce employee injuries on the job.

Over the course of 2022 and 2023, the FloridaMakes Business Advisor worked with the management team at A-1 Industries to help identify automation solutions in specific target areas of production where it would benefit the company. A-1 entered into agreements with several technology companies to design, build, and install the necessary equipment to fit the company’s needs. 

RESULTS

• 5% increase in new sales and 20% in retained
• 65 new jobs and 65 retained jobs
• $2,000,000 invested in plant and equipment
• 3% reduction in overall costs with the implementation of new automation equipment

TESTIMONIAL

With a 48,000 sq ft expansion in 2024, we now have over a 130,000 sq ft production facility in FL and through our work with the Florida Makes Network have made strategic investments in forward-thinking initiatives designed to enhance production efficiencies and output but also to significantly improve safety within our facility.  These initiatives include implementation of state-of-the-art robotic systems so that we can automate repetitive and labor intensive tasks. This not only accelerates output, but also maintains high-quality standards that our customers expect.  A-1 is poised to lead the truss industry into a new era.  Our investments in robotic technology reflects our dedication to innovation and our commitment to delivering the best products while prioritizing the safety and efficiency of our operations.

— Robert Chance, Vice President of Human Resources

THE CHALLENGE

CAE Healthcare faced the challenge of evolving its manufacturing operations to stay at the forefront of the human simulator industry. With the ambition to not only retain but also increase market share, the leadership team understood that a significant transformation was necessary. The company aimed to integrate advanced automation technologies and modern practices to optimize their manufacturing processes, improve efficiency, and reduce waste, thereby ensuring increased profitability and a stronger market position.

FLORIDAMAKES ROLE

To realize this ambitious goal, CAE Healthcare reached out to the Sarasota-Manatee Manufacturers Association, part of the FloridaMakes Network and the MEP National Network™, for project management assistance. The FloridaMakes team conducted a thorough assessment of CAE Healthcare's needs, emphasizing employee involvement, customer feedback, and supplier expectations. The team utilized a proven method for analyzing automation as a solution and orchestrated the project through meticulous planning, including integration, resource allocation, training, and change management. This holistic approach ensured that the transition to automated manufacturing was strategically aligned with the company's goals and the expectations of all stakeholders.

RESULTS

• $10,000,000 in retained sales
• 5 jobs created, 7 jobs retained
• $500,000 invested in equipment and $250,000 in workforce practices
• $2,550,000 in cost savings

TESTIMONIAL

CAE Healthcare's journey to becoming a factory-of-the-future, supported by FloridaMakes, has been nothing short of revolutionary. The transition to an Industry 4.0 manufacturing model has significantly improved our processes, efficiency, and market position. We've not only retained $10 million in sales but also realized substantial savings in inventory, labor, and materials. The strategic investments in equipment and workforce practices, managed by the FloridaMakes Team, have been pivotal to our success. This transformation has also allowed us to create new jobs and retain key staff members, underscoring our commitment to our employees and the future of healthcare simulation.

— Matt Testa, Plant Manager

ISO Certification Keeps Company in the Supply Chain

THE CHALLENGE

FLORIDAMAKES ROLE

RESULTS

• 2 jobs created and 2 retained
• $1,000,000 in new or retained sales
• $560,000 in new investment
• $10,000 in investment cost savings

TESTIMONIAL

"The FloridaMakes team was an integral part of our team acquiring our ISO 9001:2015 certification. This allowed us to receive several new orders from our existing customers along with several new customers. I highly recommend the FloridaMakes team if you are pursuing any certification status." Mike Soos

Servant Leadership Training Leads to Happier Employees and Customers

THE CHALLENGE

Servant leadership training teaches a leadership approach that focuses on creating an environment in which associates can thrive as a team while maximizing job enrichment and satisfaction, and as a result, achieve the highest levels of productivity and customer service. This is accomplished when servant leaders put service to others above their personal goals and priorities. A strong believer in taking care of and listening to their employees, JELD-WEN has a written, very specific code of conduct and expectations they call simply “The Code.” JELD -WEN turned to the Sarasota-Manatee Manufacturers Association (SAMA), part of the FloridaMakes Network and the MEP National Network™, for training in servant leadership.

FLORIDAMAKES ROLE

JELD-WEN determined that the servant leadership approach supported the tenants of their company code, which includes an expectation that managers keep communications open by encouraging associates to speak up and to show respect. It also supported the company’s values. Servant leadership is practiced in some of the top-ranking companies with those companies highly regarded and followed because of their leadership style. To ensure that their employees embrace the company’s values and code of conduct, Jeld-Wen invested in their leadership by inviting all of their senior leaders, group leaders, and team leaders to participate in 2 full days of servant leadership training. The training included lectures, videos, role playing, group discussions and pre- and post-training quizzes.

RESULTS

• $1,000,000 in increased sales due to improved product quality and happier customers
• 10 retained jobs due to increased employee satisfaction
• $50,000 due to reduction in employee turnover costs

TESTIMONIAL

We partnered with FloridaMakes for servant leadership training. The purpose of the training was to help give all leaders better tools to use in their day-to-day work as well as the tools to help them build relationships with all team members across the organization. Leadership is a privilege, and we want all our leaders to understand the main goal is to serve. If we are listening, removing obstacles and providing resources to our team members, they can be set up for success. The FloridaMakes team did a great job of facilitating fun and educational sessions to our leaders and the sessions were filled with tools they could immediately implement and use not only here at work, but with their friends and family outside of work. Slow to speak and quick to listen goes a long way, regardless of where you are. The training has helped our team become closer and helped our JELD-WEN family continue to grow.

— Mike Curtner, Plant Manager

Business Growth Program Doubles Top Line Revenues

THE CHALLENGE

The CEO’s decades-long experience in the water infrastructure industry in both the private and public sector, as well as his engineering degree, provided the opportunity for the company to innovate infrastructure maintenance solutions in hard to clean environments. A capital-intensive operation, as they expanded their capital investments the need to find new markets and customers became pronounced. However, because US Submergent operates in a niche market, leadership needed assistance in securing highly specialized and detailed market data, as well as some guidance on how to expand effectively.

FLORIDAMAKES ROLE

The Company turned to GrowFL, part of the FloridaMakes Network and the MEP National Network™, and engaged in the System for Integrated Growth (SIG) program. The SIG specialists gave them the necessary strategic market information to weigh the costs and benefits between acquiring a competitor or creating a new division. Additionally, as part of their SIG engagement, the specialists provided in-depth information on markets, competitors, and technologies, as well as HR best practices. After initially contemplating the acquisition of a select few target companies, US Submergent eventually opted to create a new Division with a more focused solution (predictive maintenance solution that provides complete visibility in full wastewater tanks). In addition, to broaden their market reach they started a new division, Sedivision, allowing them to have a greater presence in the state and be closer to their larger municipal clients.

RESULTS

• Doubled sales from $3.5M to $7M
• 18 new jobs
• Reduced downtime by 18%
• Improved policies for better attraction & retention & created a competitive compensation plan

TESTIMONIAL

Through GrowFL’s SIG program we were able to articulate clearly the relationship between clarity of job descriptions to our employees’ skills, knowledge and competencies thereby creating holistic focus, increases overall efficiencies and production output, which then increases our profitability and industry recognition. The acquisition target work was extremely helpful exercise which informed us that we were better off spinning off a new and specialized division to focus on our core strength for a narrower but more profitable market segment.

— Denver J. Stutler, Jr. , CEO

 Strategic Research For Niche Market

THE CHALLENGE

Flame Boss had marketing challenges related to their niche product. Finding the resources necessary to reach consumers in that market was a challenge. Senior management needed to better understand the market, including competitors and potential customers.

FLORIDAMAKES ROLE

As part of GrowFL’s work to support manufacturers through FloridaMakes, part of the MEP National NetworkTM, GrowFL provided Flame Boss with information pertaining to market size, competition, potential customers and leads. The market data justified further investment, which resulted in increased sales. Credible growth projections, based on the research provided, were used to secure an SBA loan.

RESULTS

• $334,000 in New Investment
• $800,000 in Increased or Retained Sales
• 10 New or Retained Jobs

TESTIMONIAL

Everyone was very professional and capable and were careful to understand our unique market. We certainly got more information than we'd be able to gather on our own."The FloridaMakes Team was extremely thorough, skilled, and deadline focused. The project allowed us to utilize a large building investment ($100k plus annually) and increase our efficiency and revenue.

— Michael Collins, Owner and CEO

 Awards Assessment Leads to Increased Sales and Jobs

THE CHALLENGE

Amerikooler has been seeing year-over-year growth, leading to increased market share for their products. The company faces challenges with the rising cost of raw materials and some supply chain disruption. The management team at Amerikooler reached out to the South Florida Manufacturers Association (SFMA), part of the FloridaMakes Network and the MEP National NetworkTM, to help identify areas of opportunity for improvement.

FLORIDAMAKES ROLE

Amerikooler is a member of the South Florida Manufacturers’ Association and was nominated to participate in the SFMA’s Manufacturer of the Year Awards process. The company received a written feedback assessment that detailed areas of opportunity, which included recommendations on improvements to their operations that would result in cost savings and increased revenues.

First, the FloridaMakes Business Advisor recommended Amerikooler purchase new processing equipment. Amerikooler’s investment improved the company’s operational efficiency, retaining sales that would have otherwise been at risk due to extended lead times created by supply chain issues and allowing the company to increase sales.The gained efficiencies led to cost savings, which offset some of the increases in raw materials and improved the company’s profit margin.

RESULTS

• 80 new jobs and 76 jobs retained
• 50% increase in new sales and 15% retained sales

TESTIMONIAL

We have been working with the SFMA organization for the last three years and participating in the Manufacturer of the Year award process. Our team here at Amerikooler has truly enjoyed working with Micah and the different auditors that have participated in our reviews, and we have embraced the challenge that comes along with the review process and presenting our processes and metric for the different categories of the audit. Most important however is what we as a team learn every time that we go through the process, it forces us to look at and scrutinize our processes to improve them and modify them. Equally important is the feedback provided by the auditors. This year we took advantage of the provided feedback and changed several processes that helped us in several areas of the business. We are looking forward again to next year and once again going through the process, we are sure that we will improve again! Also, continue with the different training to enhance our workforce skill set.
Thanks very much for all of the help."

— Juan Madariaga, Chief Operating Officer

 Factory Redesign Increases Sales and Decreases Costs

Mayhew Steel Products is the oldest punch and chisel manufacturer in the United States.  While the company has grown from being a small tool house to the industry leader, they have never lost their dedication to quality, reliability, and craftsmanship. This dedication has enabled them to become the tool of choice for certified technicians, professional mechanics, and do-it-yourselfers across the country. During Mayhew’s more than 160-year history, they have expanded both their physical size and breadth of products without losing sight of their heritage with headquarters in Western Massachusetts. The acquisition of Bestway Tools in Ormond Beach, Florida in 2019 allowed them to extend their high-quality product lines.

THE CHALLENGE

With the site acquisition, there were numerous opportunities to improve capacity and reduce quality errors, thus resulting in additional sales to the facility. Mayhew required assistance in reviewing their current state to propose the necessary changes to set them up for increased throughput in their production operations.

Mayhew Tools recently rented an expansion facility alongside their existing facility in Ormond Beach, Florida. With a shifting product revenue portfolio and newly available space, Mayhew Tools sought support to develop a plan for future production within this combined facility. The facility includes three primary activities: machining, assembly, and warehousing.

FLORIDAMAKES ROLE

Mayhew Tools reached out FloridaMakes for assistance. FloridaMakes and its team of specialists conducted a complete facility layout assessment. The assessment evaluated the current state of the entire operations, which included the machining, assembly, and warehouse areas. The deliverables from the assessment produced a future state plan for the facility with detailed analysis. Process mapping was completed for the material flow from receiving, warehouse, productions through shipping. Time-based evaluation was conducted, yielding the potential capacity of the operations. The completion of the project resulted in a plan for a new facility layout, which included improvements of the material storage, and increased efficiency in the assembly and machining areas.

RESULTS

• $75,000 Cost Savings in Labor and Investment
• 10 New or Retained Jobs:
• Over $100K in New Investment

TESTIMONIAL

The FloridaMakes Team was extremely thorough, skilled, and deadline focused. The project allowed us to utilize a large building investment ($100k plus annually) and increase our efficiency and revenue.

— Hayley Cox, General Manager