Emergency Response & Defense
Eugene, Oregon
Founded 1988
50 Employees
Efficiency That Saves Lives: Western Shelter’s Lean Journey with OMEP
Western Shelter Systems partnered with OMEP to tackle rising demand for a new product line while managing the challenges of design changes and a novel production process. Through value stream mapping, time studies, and close collaboration with employees, OMEP helped streamline workflows, standardize procedures, and identify cost-saving material alternatives. These improvements reduced waste, cut cycle times by two days per unit, and enhanced workplace safety. The project also resulted in $280,000 in cost savings and the creation of six new jobs. By training staff in continuous improvement, OMEP equipped Western Shelter with the tools to sustain progress long-term.
2 Days Per Unit
Reduced Cycle Time
6
Jobs Created
$280K
Cost Savings
Background
Western Shelter Systems, based in Eugene, Oregon, specializes in providing durable, rapidly deployable shelter solutions for emergency response, disaster relief, and industrial applications. Known for their high-quality, modular designs, they supply shelters, heating, and ventilation systems tailored to meet the needs of first responders, military, and humanitarian organizations worldwide. Their products are engineered for rugged environments, offering reliable performance in challenging conditions. With a commitment to innovation and community support, Western Shelter Systems has established itself as a trusted leader in the emergency shelter industry.
The Situation
Western Shelter faced a rapid increase in demand for a new product line. Due to several product design revisions and the newness of the novel production process, the company sought OMEP assistance to reduce waste on the line.
The Solution
OMEP started by convening stakeholders to understand the current state and desired end state. Value stream mapping as well as time and motion studies were conducted. In collaboration with production staff, OMEP identified several opportunities for improved production efficiency.
The Results
Through a series of continuous improvement cycles the production staff, guided by OMEP, streamlined product workflow, standardized processes, and identified alternate materials and methods, and implemented changes throughout the line. The portfolio of improvements has saved labor, reduced defect rates, reduced scrap material, reduced raw material costs, and contributed to increased worker safety. OMEP used the project as an opportunity to train employees on continuous improvement and the use of the improvement kata. The production staff has shown ownership of the methodology and uses continuous improvement to make further advancements.
“At Western Shelter Systems, efficiency & safety are critical to delivering life-saving solutions. Partnering with OMEP has transformed our production processes through VSM, time & motion studies & stakeholder collaboration. OMEP identified key opportunities for improvement, helping us streamline workflows, standardize procedures, and implement better materials and methods. Thanks to these efforts, we’ve reduced labor, minimized waste, and increased raw material savings. Workplace safety has also improved.”
Bryson Lee
Program Manager