Wood Products
Winston, Oregon
Founded 1986
65 Employees
Oregon Door’s Journey with OMEP
Oregon Door, a leading producer of flush interior architectural wood doors, partnered with OMEP to strengthen their lean practices and improve materials management. The management team, already committed to process improvement, wanted to advance their efficiency to better serve customers. OMEP guided the team through value stream mapping to create a clear future-state plan, with a focus on inventory, flow, and sales order processes. Improvements included a comprehensive 5S initiative across departments, lean training for all employees, and the relocation of the Skin Grading work center to improve materials flow. Reconfiguring and organizing the skins warehouse allowed staff to find materials in under a minute while eliminating obsolete stock. These changes streamlined production, improved communication, and reduced waste. As a result, Oregon Door achieved a 69% increase in throughput, a 40% decrease in labor contribution per door, and created three new jobs. With OMEP’s support, they continue their lean journey with measurable success and a stronger foundation for growth.
69%
Increase in Throughput
3
New Jobs Created
40%
Decrease in Labor Contribution Per Door
Background
Oregon Door is a leading manufacturer of quality flush interior architectural wood doors. They offer a complete product line to meet the most diverse uses and exacting standards. Oregon Door’s success is the result of years of delighting customers. As an organization, they serve architects, systems integrators, developers, distributors, contractors, and design/build teams, by not only creating quality products but also providing quality service quickly and hassle-free.
The Situation
Oregon Door Management team has a long tradition of focusing on process improvement. They sought OMEP’s support to continue their lean training, with a special focus on materials management. Additionally, the team wanted to continue applying lean principles to the flow of doors through the plant to better meet customer needs.
The Solution
OMEP partnered with Oregon Door on several key initiatives designed to eliminate waste and improve flow through hour-by-hour and on-time delivery. Beginning with the value stream mapping process, the team mapped out Current State, set a desired Future State and built an implementation plan. They focused especially on the areas of inventory, flow, and the sales order process.
The team began by conducting a current state review of inventory to reduce materials shortages and improve point of use. Additionally, they focused on 5S (Sort, Set in order, Shine, Standardize & Sustain) & 9 Waste training for all teams and departments. Lean principles were applied to administrative areas, from Sales to Scheduling.
Through the value stream mapping process, it was discovered that moving the Skin Grading work center closer to the Layup team would allow for better materials flow. Utilizing the new space available after the Skin Grading center was moved, the team reconfigured and applied 5S to the skins warehouse. The improvement allowed the team to find materials in 60 seconds or less and eliminate obsolete and low-use materials.
The Results
Oregon Door Management has made significant improvements in production efficiency, lead time and quality. As a result, they have increased throughput by 69% and experienced a 40% decrease in labor contribution per door. In addition to retaining all existing jobs, they have created 3 new jobs. Oregon Door is poised for continuous growth and success on their lean journey.
“When Brian and I began to explore the option of using OMEP to help with my initiatives here at Oregon Door, I was very pessimistic. My past experience with other Lean consultants was they would come in, give some base information, point out all your failures, and then leave. Subsequent reviews were always a beat down on what was still wrong.
I am very glad that you and OMEP do not operate in that manner. To have OMEP truly come alongside and partner with us, to get down in the trenches with us, has been both refreshing and rewarding. It has been hard work, but we can all see the progress that has been made since we began this journey together. The partnering is such a critical element to the success. I just wanted to pass on my thanks to Yvonne and OMEP. Looking forward to the continued journey!”
Kevin Hansen
Director of Operations