Worlds of Wow TMAC and Production

Thursday, October 26, 2017

Worlds of Wow TMAC and Production

At Worlds of Wow, we are continuously looking for new ways to improve our process and create better customer experiences. With the help of Joe Crosswell and TMAC, we were given great tools  to become more productive and sustainable.

Worlds of Wow TMAC and Production 
Joe Crosswell 

Worlds of Wow is one of the very few companies in the United States specializing in custom theming and play. With over 12 years experience and more that 500 projects completed, Worlds of Wow is the expert in creating original artwork and graphics to bring ideals to life! So much passion, time and talent goes into each and every project. From the very first conversation to the final piece put into place, their team gives 100% each step of the way! When customers are able to sit back and take in the delivered final masterpiece, it brings them tremendous joy to hear them say, "WOW!"

Worlds of Wow recently relocated from Argyle, TX to a larger facility in Denton. They were interested in maximizing their ability to increase production to support continued growth. Worlds of Wow contacted the TMAC office for help in improving their workflow through the manufacturing process.

Joe Crosswalk from TMAC visited the facility and after a tour of the shop recommended the implementation of some basic lean principals including reorganizing work areas to improve flow with 5S. Joe also implemented the creation of the "white board," to provide visibility of each project as it moved throughout the production process. Joe then worked with the Wow team to conduct lean wastes walks to identify activated that were not adding value to the projects completed.

Thanks to the EPA grant, TMAC was then able to provide Wow with an opportunity to deliver an onsite training program to help staff understand how to identify all types of wastes including lean, energy and environmental wastes. Value stream mapping (VSM) proved to be a tool and foundation to demonstrate the importance of the total cycle time required to complete a project.

The project included class room training followed by walks to the production floor as a cross functional team including artists, managers and production staff identified various wastes as they followed the product through its flow throughout the facility.

The team learned how to video an artist at work to determine is each step of the process was either value or non-value added in the eyes of their customers. Each step of the process was then recorded on a process breakdown sheet. Simple changes of locating tools and equipment close to the work station would allow the artist more time to create and less time walking or searching for items.

The team next took a close look at opportunities to reduce energy costs in the building. They are now also considering ways to bring natural daylight into the facility to improve staff performance. The team also took a close look at everything that was thrown away to question solid and liquid wastes were being generated. They identified an opportunity to donate waste foam pieces to a local non-profit to reduce their impact to the landfill.

The results:
Expected quantitative impacts include;

  • Utilized automated paint gun cleaning system
  • Train paint masking staff on taping methods
  • Reduced compress air leaks and operator cleaning
  • Donate foam to local non-profit to reduce impact to landfill
  • Reduced 2.25 tons sent to landfill

"TMAC helped us to realize that we always have room for improvement. We were given some great tool to become more productive and sustainable at the same time. We see the importance of taking the time each day to address our continuous improvement efforts."


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