Issue link: http://insightpub.uberflip.com/i/687405
Nicolet Plastics has been able to reduce lead times to customers to seven days — less than half the time it once took. Execution of QRM principles has allowed Nicolet to establish a niche market that has resulted in year over year average annual sales growth in excess of 10 percent during the last four years. Nicolet Plas cs, Inc.: A fresh twist on training INSIGHT INNOVATION AWARD WINNER: PEOPLE If you've flown on an airplane, drank a cra beer, cruised on a lake, used a humidifier in your home or had an MRI, you've experienced Nicolet Plastics. Based in Mountain, Wis., the custom plastics injection molding company specializes in low to moderate volumes, a wide range of materials and product mix. Prior to 2010, Nicolet Plastics, was struggling to compete globally and domestically in the commodity-based market for plastic injection molding, saddled with large inventories and related debt. e company reinvented itself by adopting Quick Response Manufacturing, an adaptation of Lean Manufacturing. e new approach called for clear communication and buy-in from employees to be successful. Judges said, "e company is 'changing the plastics landscape focused on strategic variability, single-piece flow, low volume and high complexity without losing sight that their team comes first."' Judges cited the following innovations involving people, from its 75 employees to its customers: • Nicolet Plastics University for customers — to train and guide customers in the understanding of injection molding and how the process factors into their needs. • Skills matrix and cross training of the workforce — rewarding people for gaining new skills with compensation, setting aside time for employees to be trained; cross- training employees for flexibility to meet production demands. e company captures video of its manufacturing steps by outfitting skilled employees with GoPro cameras and requires new employees to view them in its training. • e skills matrix has resulted in the elimination of job descriptions; only skill levels differentiate workers, who earn "apples," which correlate increased skills with higher pay. (Apples refer to the company's Apple Rewards Program; CEO Macintosh's name was the inspiration.) • A robust internship program — free housing, involvement in customer- facing experiences, broad exposure to different equipment and processes. ONLINE: Insightonbusiness.com/thinc CLICK to see a video about Nicolet Plastics, Inc. Nicolet Plastics, from left: John Ogorek, Business Development Manager Bob Gafvert and Doug Baril.