Lean Manufacturing Propels Aerofil Technology Inc. Forward
Leader in Custom Packaging and Filling Doubles Business Capacity with New Company-wide Continuous Improvement Processes

ST. LOUIS, MO, August 14, 2010 /24-7PressRelease/ -- Aerofil Technology Incorporated (ATI), America's resource for custom packaging, and liquid and aerosol filling, has experienced a 100% increase in productivity and double digit inventory turns due to the company's bold new direction of Lean Manufacturing. ATI is making huge strides in the industry by adopting the principles of the Toyota Production System (TPS), which focuses on streamlining the production process through the total elimination of waste and improvement of overall customer value.

"When we first introduced Lean Manufacturing to our employees, I knew it would be a challenge," said Pat Bergin, President of ATI. "Out of every 100 companies who undertake this process, 96 either fail or quit within 18 months. However, having the unequivocal full support of ATI's ownership was the key to our long-term success and sustainment. Having both led and participated in Lean transformations around the world, I know that the commitment must come from the top of an organization or it could actually hurt the emerging culture."

The company began the Lean journey by evaluating its "current state" and mapping the entire administrative information flow processes to generate a blueprint that identified significant performance improvement opportunities using Kaizen bursts. The four-pronged approach includes:
· Value Stream Mapping
· 6S (Safety, Sort, Scrub, Set in Order, Standardize, Sustain)
· SMED (Single Minute Exchange of Die)
· Visual Management
Each of these components lends to the successful daily operation of the packaging plant. The increased business and overall production capability is the direct outcome of implementing these processes on a company-wide scale.

"Our commitment to customer service and environmental safety provides a solid foundation for a successful business," said Bergin. "Our capabilities, customer base and facility size have grown exponentially during the past 10 years. Lean Manufacturing aligns perfectly with our goals and standards, so the transition came naturally."

The Single Minute Exchange of Dies (SMED), also known as equipment changeover rates, delayed production between 45 minutes and several hours prior to operating with Lean standards. Now, ATI completes many of its changeovers in 10 minutes or less; more than a 500% improvement. Each production line can have more than 400 changeovers per year and Lean has proven to have a major, positive impact on efficiency, customer delivery and inventory turns. This has unleashed a tremendous amount of equipment capacity while reducing inventories throughout the entire supply chain.

In addition to being widely recognized as following Lean Manufacturing principles, ATI offers a number of services including custom packaging, liquid and aerosol filling, warehousing and distribution, and retail solutions. The company produces a full range of products for the Automotive, Personal Care, Insecticide and Home Improvement markets. For additional information on ATI's Lean Manufacturing system, please visit www.aerofil.com.

Press Release Contact Information:

Monica Howald
Black Twig Communications
Account Supervisor
7711 Bonhomme Ave. Suite 400
St. Louis, MO
USA 63105
Voice: 314.255.2340x108