ALPHARETTA, Ga. — December 15, 2016 — Shopfloor Support LLC has announced that Hyperlite Mountain Gear Inc. has successfully adopted its Shopfloor Eye™ real-time shop floor control solution at its Biddeford, Maine, facility. After using the wireless production management software for just three months, the leader in ultralight packs, tents, shelters and other outdoor adventure gear reports measurable gains in overall productivity and increased process visibility and control.
“With growth nearly doubling each year, we knew that we needed to deploy the best engineering and systems available to meet demand and cost-effectively produce here in the USA,” explained Hyperlite Mountain Gear Director of Operations John Schafer. “While we have always been committed to continuous improvement, the Shopfloor system gives us the opportunity to have a “new conversation” on our shop floor; one that is based on coaching around real-time production information, visibility and profitability. We have quickly found that this system empowers us to consistently meet production standards, balance our production line, and guarantee maximum efficiency.”
To rapidly implement and prove the benefits of the new system, Schafer, a veteran of global manufacturing, set up a new team-based “Pack Express Line” manufacturing cell. While workers are not paid on industry-traditional piecework incentives, engineering studies were conducted to determine efficient production standards for each of the many steps involved in producing backpacks. Based on the tremendous results achieved, Hyperlite Mountain Gear is making plans to deploy the Shopfloor system across its entire production operation next month.
“Before Shopfloor, managing production was like driving a car by looking through the rear-view mirror,” continued Schafer. “Now we are looking forward with the benefit of seeing and being able to respond to any potential obstacles. We have never had this level of shop floor information and control before; especially in such a cost-effective solution.”
Shopfloor Support is further developing its Simple BOM™ capabilities to enable Hyperlite Mountain Gear pre-production teams to use their tablets to scan work orders and more accurately pick all components (often upwards of 60 parts) needed to produce packs. Shopfloor also plans to develop software tools to eliminate parts picking errors by verifying precise bins and shelf locations, and to manage work-in-process collection areas where specific products can be staged for specific operations or processing.
“We applaud the Hyperlite Mountain Gear team for their commitment to Made in USA, their production teams and their efficiency,” noted Shopfloor Support Partner Justin Hershoran. “We enjoy their partnership and look forward to a long and highly productive relationship.”