Milbank Lean Team Sparks Manufacturing Efficiency Across Operations

At Milbank Manufacturing, our commitment to continuous improvement runs deep. Guided by our Lean Manufacturing initiative, we’re streamlining processes, reducing waste, and empowering teams across all facilities to deliver smarter, faster, and more efficient results.
Our Director of Lean Transformation, Casey Gowler, and our Lean team are continuing to lead Kaizen events and process improvements to drive measurable change across our operations in all locations.
 

Lean in Action: Recent Improvements Across Milbank

Milbank’s process enhancements and product innovations are the main focus for our Lean Transformation Team. Here are just a few examples of recent events hosted by the team to zero in on areas that need improvement:
 

Kansas City: Reducing Wait Time and Improving Flow

Our Wire Department Kaizen focused on reducing wire wait time in Final Assembly. By installing a second wire stripper, modifying equipment, labeling racks, and improving tooling, the team achieved a 28% reduction in wait time, from 84 minutes per week to just 60.

In the Breaker Area, a Kanban system was established to maintain stock of top breakers. The result was consistent inventory levels for the top 14 breakers through IFS Kanban, ensuring production continuity and reduced downtime.

The EMK Press Area also saw improvements in manufacturing efficiency. With defined material lanes and process reviews, the team worked to eliminate bottlenecks and increase throughput by 20%.

Meanwhile, a Line Side Sequencing Kaizen in Final Assembly focused on improving material delivery timing. By generating and implementing new sequencing ideas, the team is enhancing material flow and supporting on-time production.
 

Concordia: Smarter Layouts, Faster Results

Our Transocket Lift Event targeted a 10% reduction in cycle time, and the results spoke for themselves. By redesigning the line layout, introducing ergonomic lift tables, and balancing manpower, the Concordia team not only reduced cycle times on multiple lines but also improved overall manufacturing efficiency and created a more ergonomic, efficient workspace.

During the Drawing and Print Lift Event, the team streamlined drawing retrieval and initiated an engineering “drawing blitz,” reducing time spent searching for materials and improving access to critical information.

The Power Distribution and Controls Kanban Flow Lift Event enhanced daily output through supermarket staging before paint, improved stocking levels, and revamped Kanban cards. Output increased to an average of 23 units per day, with additional gains planned.
 

Corporate: Strengthening Data and Collaboration

At the corporate level, a Product Information Management (PIM) Kaizen brought teams together to refine processes in InRiver and improve customer-facing product data on our website. The newly formed PIM Council defined roles, responsibilities, and standard work, ensuring more accurate, consistent product information for customers and partners alike.
 

What’s Next: Continuing the Lean Journey

The journey doesn’t stop here. Upcoming Kaizen events will focus on Power Distribution and Controls, Welding, Final Assembly, and Sales-to-Production process improvements across Kansas City, Concordia, and El Dorado.

These initiatives are designed to further eliminate waste, improve communication, and strengthen cross-functional collaboration, all while enhancing the customer experience.
 

Building a Stronger Future Through Lean Thinking

Milbank’s Lean Manufacturing initiative is about more than process improvement, it’s about people, teamwork, and a shared commitment to excellence. Every Kaizen, every improvement, and every small win contributes to a larger goal: building a smarter, more efficient, and more sustainable Milbank.

As we continue to refine our operations, one thing remains constant, our dedication to delivering quality, reliability, and innovation to our customers through the power of Lean.