Case Study: Metal Processing Company achieves 6% productivity gain and 90% reduction in nonconformances with iGrafx

Operations Improvement Through Effective Employee Engagement

Metal Processing Company, a multi-location manufacturer of formed metal products with more than 35 years in business, faced customer pressure for new capabilities and higher service levels while needing faster, company-wide adoption of best practices. Management wanted rapid, measurable improvements and broad employee buy-in to capture retiring expertise and standardize processes. To achieve this they engaged 4aBetterBusiness and the iGrafx business process management toolset to accelerate change.

4aBetterBusiness used a process-driven, implementation-focused approach and iGrafx process visualization to document processes, distribute work instructions, and engage employees across all sites. With iGrafx-enabled process maps and photographic standard work, the company achieved a 6% productivity gain in core manufacturing, a 90% reduction in nonconformances for a key account, reduced scrap, and identified an 11% increase in warehouse throughput—delivering rapid, measurable improvements and sustained employee ownership of continuous improvement.