Firth Rixson Limited

Firth Rixson Monroe (FRM) is the Rochester facility of Firth Rixson, Ltd., a UK-based operator of forging, casting, specialty rolling, melting and fabricating plants.  FRM is a primary source for structural ring, rotating and bearing components for the aerospace and power generation industries.  At the beginning of its relationship with High Tech Rochester (HTR), the plant employed 77 people.  The business was hit hard by the events of 9/11, with sales dropping almost 40%.

Situation:

In 2000 FRM management, with the assistance of HTR and a local consulting firm, developed an assessment of current performance and improvement opportunities, not only in manufacturing, but also in the quality, engineering, information systems, sales & marketing, human resources and finance functions.  The needs identified in this initial study set in motion a series of plant-wide improvement projects that is on-going and has transformed the culture and competitive position of FRM dramatically.

Solution:

In October 2000, following up on the performance assessment, HTR assisted Firth Rixson in applying for a $40,000 grant from New York State’s Industrial Effectiveness Program.  The grant, matched by company funds, was used to develop and implement a plant-wide Continuous Improvement program during 2001.  FRM management then saw that Lean techniques would enable the company to capitalize on the Continuous Improvement work.  The business impact of 9/11 dramatically underlined the need for further efficiency improvements.  Thus, in 2002, the company worked with HTR and Rochester Works! (the local Workforce Investment Board) to obtain a $39,237 state training grant and introduce Lean techniques to the workforce.  By mid-2005, FRM management felt that their Lean program was becoming stale and needed to be revitalized in order to continue to generate optimal results.  The company again worked with HTR and one of HTR’s local Lean consulting groups to obtain a second $40,000 state Industrial Effectiveness grant in support of an 18 month project designed to drive Lean thinking deep into the FRM culture.

Results:

After five years of continuous Lean development, inspired by far-sighted management and supported by the resources of HTR, New York State, Rochester Works! and local consultants, FRM is uniquely competitive within the Firth Rixson Ltd. Organization.  Work is being shifted to it from other company facilities in the U.S.  Its Lean capabilities recently led the parent company to invest $2.5M in new capital equipment.  Sales have increased 375% from the post-9/11 low.  While employment has risen to 83, sales per employee have soared 198% since the initial grant application in 2000.  Mary Lindsay, FRM’s Human Resources Executive says “The training we received through the grant funding was crucial to our success.  Lean manufacturing is a culture now and it makes everything from training to developing ISO processes more efficient and easier. Continuously improving has become a way of life.”

Testimonial:

“Without Lean change, this plant would not be here.” Michael Carr, General Manager.