Research indicates two out of three shoppers do not know which brands to choose. However, a Missouri company is helping shoppers to decide by taking the extra time to understand their goals as well as presenting new ideas and creative techniques that guarantee brand results. Results companies can easily track and monitor to see and prove their return on investment (ROI).

For more than a decade, PrintFlex Graphics has been manufacturing in-pack and one-pack materials for consumer package goods. Their customized product line includes instant redemption coupons, folded booklets, FDA-approved inserts, pressure sensitive labels, stickers, games and sweepstakes coupons.

Late in 2008, the company asked Missouri Enterprise, a not-for-profit organization dedicated to helping Missouri's small businesses succeed – and a partner of the Missouri Department of Economic Development – to conduct a lean, clean and green assessment of its St. Louis manufacturing plant. The program utilizes proven lean enterprise waste identification and elimination tools and techniques to evaluate operational process waste material disposal and energy use and recommended potential improvements.

The assessment identified several areas for potential improvement for the two-time recipient of Time Inc. ‘5000 America's Fastest Growing Private Companies’ award. In waste disposal, it was suggested that the company attempt to sell "matrix waste," or leftover paper, plastic and adhesive material, to companies that manufacture composite lumber products. Also, as a result of a Missouri Enterprise recommendation, the company has purchased a cardboard baler and will recycle more than 11,000 pounds of cardboard a year at an annual saving of approximately $3,500. As a result of the assessment, the company is also investigating ways to recycle several thousand wood pallets annually.

The assessment also included several specific energy and cost saving recommendations related to air conditioning, use of compressed air, lighting and insulation that the company is planning to implement.

The manufacturing process improvement section of the assessment has left Print Flex Graphics to initiate a lean enterprise transformation program, which began recently with an introduction to lean enterprise seminar. The day-long seminar, which includes a hands-on simulation, gave all company employees an overview and understanding of key lean enterprise tools and techniques used to identify and eliminate waste throughout a company’s operations.

In the next phases, Missouri Enterprise Lean Enterprise specialists will help the company create current and future state value steam maps. A current state map is a graphical representation of all activities, both value-added and non-value-added, that are part of the company’s operations. A future state map is a guide to the actions that can be taken to eliminate waste and improve the company’s progresses.

Based on the value streams maps, Missouri enterprise will help company management prioritize continuous improvement opportunities and conduct a series of very intense and highly focused continuous improvement events called Kaizens, to eliminate non-value added activities.

These Kaizen events will utilize a variety of lean enterprise tools including 5S workplace organization, cellular flow manufacturing, setup reduction and total productive maintenance. Missouri Enterprise will also provide Lean enterprise support and mentoring as needed to help PrintFlex Graphics sustain the continuous improvement gains it makes.

"PrintFlex Graphics has a very strong commitment to being an environmentally friendly company in our processes and products," said DED Director Linda Martínez, "but we also anticipate that this diagnostic program will result in recommendations that will generate bottom line cost savings."