{"id":27,"date":"2015-03-25T00:39:30","date_gmt":"2015-03-25T00:39:30","guid":{"rendered":"http:\/\/www.pinnacleeg.com\/iso\/case-study-roman-manufacturing\/"},"modified":"2015-04-08T16:13:13","modified_gmt":"2015-04-08T16:13:13","slug":"case-study-roman-manufacturing","status":"publish","type":"post","link":"http:\/\/www.pinnacleeg.com\/iso\/case-study-roman-manufacturing\/","title":{"rendered":"Case Study &#8211; ISO 9001, ISO 14001 &#038; Lean &#8211; RoMan Manufacturing"},"content":{"rendered":"<p><strong>Outcome:\u00a0\u00a0\u00a0 <\/strong><a title=\"www.romanmfg.com\" href=\"http:\/\/www.romanmfg.com\/\" target=\"_blank\">RoMan Manufacturing<\/a> uses Pinnacle&#8217;s <a title=\"Lean Quality Management System\" href=\"http:\/\/www.pinnacleeg.com\/ISO-9001-9000-Training-Consulting.php\/page\/services\/service\/quality-management-systems-QMS\" target=\"_blank\">Lean QMS\u00ae<\/a> and <a title=\"Lean Environmental Management System\" href=\"http:\/\/www.pinnacleeg.com\/ISO-14000-14001-Training-Consulting.php\/page\/services\/service\/environmental-management-systems-EMS\" target=\"_blank\">Lean EMS\u00ae<\/a> to develop an <a title=\"Integrated Management System\" href=\"http:\/\/www.pinnacleeg.com\/shp-integrated-management-systems.php\/page\/services\/service\/integrated-management-systems\" target=\"_blank\">integrated quality and environmental management system<\/a>, achieve <a title=\"ISO 9001 &amp; ISO 14001 Certification\" href=\"http:\/\/www.pinnacleeg.com\/shp-integrated-management-systems.php\/page\/services\/service\/integrated-management-systems\" target=\"_blank\">ISO 9001 and ISO 14001 certification<\/a>, and support <a title=\"Lean Manufacturing\" href=\"http:\/\/www.pinnacleeg.com\/shp-lean-and-six-sigma.php\/page\/services\/service\/lean-and-six-sigma\" target=\"_blank\">Lean Manufacturing<\/a> transformation.<\/p>\n<p><strong>Industry:\u00a0\u00a0\u00a0\u00a0 <\/strong>Automotive, Telecommunication, Electronics, Manufacturing<\/p>\n<p><strong>Objectives:<\/strong><\/p>\n<ul>\n<li>Improve and simplify the existing <a title=\"ISO 9001 Certification\" href=\"http:\/\/www.pinnacleeg.com\/ISO-9001-9000-Training-Consulting.php\/page\/services\/service\/quality-management-systems-QMS\" target=\"_blank\">ISO 9001 quality management systems<\/a>.<\/li>\n<li>Make the quality management system value-added for running the business.<\/li>\n<li>Integrate with and support Lean Manufacturing transformation<\/li>\n<li>Develop a practical Environmental Management System and achieve <a title=\"ISO 14001 Certification\" href=\"http:\/\/www.pinnacleeg.com\/ISO-14000-14001-Training-Consulting.php\/page\/services\/service\/environmental-management-systems-EMS\" target=\"_blank\">ISO 14001 certification<\/a>.<\/li>\n<\/ul>\n<p><strong>Approach:<\/strong><\/p>\n<ul>\n<li>Use Pinnacle&#8217;s <a title=\"Lean QMS - ISO 9001 Implementation\" href=\"http:\/\/www.pinnacleeg.com\/sspqms-lean-qms-curriculum.php\/page\/services\/service\/leanqmscurriculum\" target=\"_blank\">Lean QMS\u00ae methodology<\/a> to simplify existing QMS documentation and maintain <a title=\"ISO 9001 Certification\" href=\"http:\/\/www.pinnacleeg.com\/ISO-9001-9000-Training-Consulting.php\/page\/services\/service\/quality-management-systems-QMS\" target=\"_blank\">ISO 9001 certification<\/a>.<\/li>\n<li>Use Pinnacle&#8217;s <a title=\"Lean EMS - ISO 14001\" href=\"http:\/\/www.pinnacleeg.com\/ISO-14000-14001-Training-Consulting.php\/page\/services\/service\/environmental-management-systems-EMS\" target=\"_blank\">Lean EMS\u00ae methodology<\/a> to integrate the EMS with the QMS and achieve <a title=\"ISO 14001 Certification\" href=\"http:\/\/www.pinnacleeg.com\/ISO-14000-14001-Training-Consulting.php\/page\/services\/service\/environmental-management-systems-EMS\" target=\"_blank\">ISO 14001 certification<\/a>.<\/li>\n<\/ul>\n<p><strong>Benefits:<\/strong><\/p>\n<ul>\n<li>A management system that is more easily navigable than the previous text-based system.<\/li>\n<li>Increased personnel involvement in relating the process to every part of the business.<\/li>\n<li>A seamless, rapid integration of <a title=\"ISO 14001 Integration\" href=\"http:\/\/www.pinnacleeg.com\/ISO-14000-14001-Training-Consulting.php\/page\/services\/service\/environmental-management-systems-EMS\" target=\"_blank\">Lean EMS\u00ae (ISO 14001)<\/a> with the visual Lean QMS\u00ae resulting with a single integrated management system.<\/li>\n<\/ul>\n<p><em>&#8220;For many employees, having to consult a three page single spaced document for every procedure was drudgery. The visual system makes everything easy to relate to. We actually started getting input from people.&#8221;<\/em><\/p>\n<p align=\"right\"><em>Kendall Ymker, Management Representative<\/em><\/p>\n<p><strong>Lean QMS\u00ae and Lean EMS\u00ae Make Everyone Part of the Quality Process<\/strong><\/p>\n<p>RoMan Manufacturing is a leading manufacturer of transformers, power supplies, switches, and inverters. Their multiple departments occupy 3 buildings in Southwest Grand Rapids, Michigan. RoMan began to explore making a commitment to a formal quality management program when one of their automotive customers put a group of its suppliers on a timeline for QS 9000 T&amp;E. After discovering that the customer&#8217;s QS 9000 T&amp;E requirement didn&#8217;t apply to their operation, RoMan began to pursue <a title=\"ISO 9001 Certification\" href=\"http:\/\/www.pinnacleeg.com\/ISO-9001-9000-Training-Consulting.php\/page\/services\/service\/quality-management-systems-QMS\" target=\"_blank\">ISO 9001 certification<\/a> and contacted outside consulting firms to assist them.<\/p>\n<p>Early in the process they reviewed the Pinnacle Lean QMS\u00ae and agreed that there were aspects of the Lean QMS\u00ae that would simplify their certification and possibly be more appealing to present to the employees. However, they began normal preparation for their registration audit and development of a text based system. As the process continued and the quality manual grew in content, the certification activity began to feel like a management-only team exercise. There was no lack of process material available but according to Kendall Ymker, Management Representative, it seemed like just that&#8230;&#8221;material, that didn&#8217;t have a feel linking it to the business.&#8221; It wasn&#8217;t that there was negative feedback regarding the <a title=\"ISO 9001 Certification\" href=\"http:\/\/www.pinnacleeg.com\/ISO-9001-9000-Training-Consulting.php\/page\/services\/service\/quality-management-systems-QMS\" target=\"_blank\">ISO 9001 certification process<\/a>, the personnel just weren&#8217;t in tune with what was taking place in the <a title=\"ISO 9001 Consulting\" href=\"http:\/\/www.pinnacleeg.com\/sspqms-lean-qms-curriculum.php\/page\/services\/service\/leanqmscurriculum\">ISO 9001 implementation process<\/a>.<\/p>\n<p>About 5 months into the process after a successful registration audit, RoMan decided to convert to Pinnacle Enterprise Group&#8217;s visual Lean QMS\u00ae. The conversion took about 5 more months, but the results were more than worth the effort, according to Operations Manager Greg Garthe. &#8220;The text-based books and manuals were good, but no one really took the time to use them. It was difficult to look things up on the computer. The visual based system was much easier to follow. People can actually see what&#8217;s happening.&#8221;<\/p>\n<p>With the conversion to Pinnacle Lean QMS\u00ae, the RoMan quality manual went from 100 pages of single spaced text, to a three page graphical overview, called the Lean QMS\u00ae Map. The Lean QMS\u00ae Map is then linked to 20 pages of process maps that describe every core and support process. &#8220;It was like going from the dark ages to the enlightenment,&#8221; stated Greg Garthe. &#8220;The visual system is very powerful.&#8221;<\/p>\n<p>With the visual system created by the Lean QMS\u00ae, the <a title=\"ISO 9001 Certification\" href=\"http:\/\/www.pinnacleeg.com\/sspqms-lean-qms-curriculum.php\/page\/services\/service\/leanqmscurriculum\" target=\"_blank\">ISO 9001 certification<\/a> initiative was no longer a management team only exercise. The team began to receive input from a wide variety of personnel. &#8220;People actually stopped just sitting around the table and became involved,&#8221; said Kendall Ymker.<\/p>\n<p>Not only did everyone begin sharing ideas for the certification process, but the system became an important tool for running the business. Even though there was no longer a customer requirement driving the need for certification, the leadership team and personnel alike felt the Lean QMS\u00ae truly represented the operation, and at the same time became the operation. RoMan uses it to run the business because it&#8217;s both the easiest way and the best way. &#8220;We live it, it&#8217;s what we do,&#8221; states Garthe.<\/p>\n<p>For RoMan, beginning with the Lean QMS\u00ae also provided an important economy of scale for their Environmental Management System. They were able to pick any core process and develop its environmental aspects easily and visually. Using Pinnacle Enterprise Group&#8217;s Lean EMS\u00ae, RoMan was able to complete their <a title=\"ISO 14001 Certification\" href=\"http:\/\/www.pinnacleeg.com\/ISO-14000-14001-Training-Consulting.php\/page\/services\/service\/environmental-management-systems-EMS\" target=\"_blank\">ISO 14001 certification in less than 4 months<\/a>, thanks to the system and culture which evolved during the <a title=\"ISO 9001 Consulting\" href=\"http:\/\/www.pinnacleeg.com\/sspqms-lean-qms-curriculum.php\/page\/services\/service\/leanqmscurriculum\" target=\"_blank\">ISO 9001 implementation process<\/a>.<\/p>\n<p>When asked whether using the Pinnacle system is cost effective, Ymker says, &#8220;It&#8217;s not even a question mark&#8230;.just get it done!&#8221; Both the company leadership and personnel agree that it is easy to see the value.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Outcome:\u00a0\u00a0\u00a0 RoMan Manufacturing uses Pinnacle&#8217;s Lean QMS\u00ae and Lean EMS\u00ae to develop an integrated quality and environmental management system, achieve ISO 9001 and ISO 14001 certification, and support Lean Manufacturing transformation. Industry:\u00a0\u00a0\u00a0\u00a0 Automotive, Telecommunication, Electronics, Manufacturing Objectives: Improve and simplify the existing ISO 9001 quality management systems. Make the quality management system value-added for running [&hellip;]<\/p>\n","protected":false},"author":2,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[3,4,5,6,7,8,10,11,12,13,14],"tags":[],"class_list":["post-27","post","type-post","status-publish","format-standard","hentry","category-as9100","category-continual-improvement","category-iso13485","category-iso14001","category-iso9001","category-lean-six-sigma","category-pinnacle-enterprise-group","category-process-improvement","category-quality-management-system","category-tl9000","category-ts16949"],"_links":{"self":[{"href":"http:\/\/www.pinnacleeg.com\/iso\/wp-json\/wp\/v2\/posts\/27","targetHints":{"allow":["GET"]}}],"collection":[{"href":"http:\/\/www.pinnacleeg.com\/iso\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"http:\/\/www.pinnacleeg.com\/iso\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"http:\/\/www.pinnacleeg.com\/iso\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"http:\/\/www.pinnacleeg.com\/iso\/wp-json\/wp\/v2\/comments?post=27"}],"version-history":[{"count":1,"href":"http:\/\/www.pinnacleeg.com\/iso\/wp-json\/wp\/v2\/posts\/27\/revisions"}],"predecessor-version":[{"id":55,"href":"http:\/\/www.pinnacleeg.com\/iso\/wp-json\/wp\/v2\/posts\/27\/revisions\/55"}],"wp:attachment":[{"href":"http:\/\/www.pinnacleeg.com\/iso\/wp-json\/wp\/v2\/media?parent=27"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"http:\/\/www.pinnacleeg.com\/iso\/wp-json\/wp\/v2\/categories?post=27"},{"taxonomy":"post_tag","embeddable":true,"href":"http:\/\/www.pinnacleeg.com\/iso\/wp-json\/wp\/v2\/tags?post=27"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}