BriskHeat® is a 68-year-old manufacturer of flexible surface heating elements and controls/accessories for unlimited applications in industrial, commercial and specialty applications. Petrochemical, semiconductor, food processing, biotech, aviation, steel, laboratory, power generation and many other industries have found their solution with BriskHeat’s heating products. A broad range of experience in solving your applications for viscosity control, condensation prevention, process heat, and freeze protection has allowed BriskHeat to become the world-wide leader in flexible surface heat and heat trace applications for piping, vessels, pumps, valves, and other objects.
Historically, the process used to design the specialty heating blankets manufactured by BriskHeat was inefficient and had long lead times. BriskHeat’s clients range from very large international clients to smaller operations. Servicing all clients and meeting their expected/needed delivery schedules was complicated, resulting in long lead times, overtime costs and rework. Customer satisfaction was at risk and costs associated with wastes were eroding business profitability. A new process to manage and streamline order processing, engineering and manufacturing work flows was needed. The desire was to reduce lead times for the engineering and design processes by 30% (from an average of 33 days to 23 days).
PolymerOhio was engaged by BriskHeat’s Quality team to execute a Lean Six Sigma project to measure/map the performance of the current state, identify wastes (time as well as physical wastes) and to guide the engineering, operations and quality teams through a methodical DMAIC (Define, Measure, Analyze, Improve and Control) project to improve the engineering and operational processes.
The Lean project had a direct result of dramatically improved turn-around times for BriskHeat’s engineering processes. Historically, engineering turn-around required on average of 33 days. As a result of this project, that time has been reduced to a mere 8.2 days, significantly better than the targeted 30% improvement that BriskHeat sought to achieve.
The company also achieved cost savings as a result of greatly improved efficiencies and a reduction of errors in engineering designs and projects that may have been released prematurely to the shop floor, causing waste. Greater customer satisfaction is anticipated because of faster deliveries, more consistent quality, and predictable product performance.