Convinced that Trainer’s more than 30 years of experience helping businesses and industrial companies find efficiencies could translate to the service area, Kilp went to the Town Administrator for approval of a contract from Trainor and his associates.
Circle Y Saddles, Inc. currently operates a saddle manufacturing operation in Yoakum, Texas. The Texas facility has been manufacturing saddles and other equestrian related products for almost 50 years. In 2004 Trainor and Associates began working with our leadership toward the implementation of lean manufacturing principles and processes.
Prior to our transformation, our saddle manufacturing lead time averaged 10 weeks. We also manufactured saddles in batch quantities of 3 or more. The average labor content was over 12 hours per unit and we struggled with meeting our quality standards.
Over a period of approximately 12 months while working with Trainor and Associates we experienced a phenomenal transformation. We were able to reduce our lead time to 2.5 weeks while making single units. Our average labor content fell to less than 8 hours and our quality soared past our standards.
These improvements allowed us to improve our customer service greatly, reduce our work-in-process inventory cost by almost 60% and finished goods by 50%. While we continue our journey in constant improvement we are so far from where we were it seems almost unfathomable.
Thanks to Bob and his team for helping Circle Y continue its global competitive viability while manufacturing products in the US.
Steve Tucker Chairman, CEO
I cannot say enough great things about Bob and Brian. As the director of distribution for a mid-size direct to consumer business we faced several barriers with addressing capacity, productivity and new business launches. The size of our company did not allow for a full time IE – but we absolutely needed one if we were to remain competitive and hit our business plan. Bob and Brian were the answer and brought not only their technical skills into our operation but numerous insights gathered while supporting others with similar challenges. They did such a great job that every major problem or expansion we tackled was always prefaced with “what does Bob think we need to do?”
Rob Reynolds
Director, MTDC 946
