Big things have been happening at Monti, Inc. during the second half of 2011. Our employees have endured an enormous workload, excessive heat, changes and even more changes. The summer of 2011 brought unforeseen challenges to Monti employees. While the shop faced a large workload, our Cincinnati facility experienced an oppressive heat wave with heat indexes reaching 100-110 degrees. In fact, Cincinnati tied a 110-year-old record for the longest consecutive hot spell, which lasted 17 days. Despite the heat, Monti employees were working longer hours, shipping more parts and bringing in record-breaking sales.
The increase in throughput at our Cincinnati facility affirmed the need for improvements in our shipping and warehouse departments. Monti sought the help of Definity Partners to facilitate another lean transformation; this project focused solely on materials management. Three important goals for the transformation were set during a kickoff meeting: 1) Reduce stocking, picking and shipping errors by 90%; 2) Develop a standard process for materials management from order entry to shipment; and 3) Improve inventory control and accuracy.
All out-bound shipping and warehouse functions were moved to the second floor and underwent a complete organizational overhaul. This was possible because our building is built into a hillside, which enables the 2nd floor to have loading docks. The first stage of the transformation was a massive clean sweep of the upstairs area and inventory. Anything that had not been touched in two years was thrown away, including finished parts, raw stock, and even old stamping dies.
Once cleared, an efficient layout was established conducive to the pick/pack process with clearly labeled racks and accurately stocked shelves. An important phase of the project was to create a visual management system that was measurable. To increase visibility, the team started to ship from an open order report rather than individual reports provided by account managers. The new scheduling process is simply measured by lines shipped from the open order report.
As machine technology advances, so must Monti employees’ skill sets. State-of-the-art machinery is only as capable as its machinists. Monti strives to provide extensive training to our machinists, both in Cincinnati and the Carolinas. Training not only empowers Monti employees, but also increases the company’s machining abilities.
Aside from new machines, investments have been made to upkeep the Cincinnati facility. After a soggy October, the need for a new roof was ever apparent. What is referred to as the ‘Great Flood’ brought unanticipated challenges to the warehouse improvement efforts. The shipping move also required that the building’s upper shipping docks and driveway be repaved. Additionally, a much larger cafeteria is being constructed where stock was once housed to provide employees a comfortable place to take their breaks and to hold company-wide meetings.
Monti Greenwood has settled into their new facility since the big move in early 2011. With the added manufacturing area, a Mazak Turbo X48 CNC Laser has been transferred from the Cincinnati plant to the Southern facility. Specializing in sheet metal fabrication, the combination of the newly added laser and two pre-existing water jets enhances Greenwood’s machining flexibility.
Looking back on 2011, it is safe to say that this has been the company’s busiest year yet. The work load has been on overdrive since July, breaking record sales month to month. Throughout the year, many improvements have been made in not only our processes, but in our people. Meanwhile, Monti has continued to purchase the latest manufacturing equipment to meet the needs of our customers. After all the hard work and long hours this year, we hope to set ourselves up for continued success in 2012.
Boschert CU Profi CNC Bus Bar Punching Machine 
HAAS VF-SS 5 Axis VMC: Super-Speed Vertical Machining Center50” X 26” X25”, 40 taper, 30-hp vector drive, 12,000 rpm 
SolidWorks 3D CAD Design Software 
