2022
“We knew we needed additional space, but we also knew we had to design it effectively. The Value Stream Mapping performed with the Nebraska MEP helped Wilson Case identify better processes, helped us manage our inventory much more effectively, limit wasted time and scrap, and increase our profitability. It’s amazing-everything is so different than before, and we continue to implement new processes.”
Doug Huffaker
President, Wilson Case, Inc.
Value Stream Charts Course to Efficiency and Profits for Wilson Case, Inc.
Wilson Case engineers custom shipping case solutions that make shipping products safer, smarter, and easier. They are a leading manufacturer of engineered, custom ATA-300-Category-1 shipping case solutions that protect the costliest products during transit or storage. The company specializes in custom reusable shipping cases that replace wood crating and custom crates. Founded in 1976, Wilson Case has built a strong reputation for service, vision, innovation, durability, and reliability. These same principles drive the manufacturing of custom shipping case solutions for costly medical devices and the most fascinating space missions. Employing 25+ associates in Hastings, Nebraska, Wilson Case is ISO 9001:2015 Certified.
The Situation
Wilson Case President Doug Huffaker identified delays in the company’s production process, inadequate production space and inventory control issues. He consulted with the Nebraska MEP to find solutions to improve production, get a better handle on inventory, and boost overall profitability.
The Solution
Brad Blair, Nebraska MEP’s Industrial Liaison Officer, went onsite to conduct a value stream mapping process with the Wilson Case team over a two-day session. This exercise identified not only the need for additional space, but a redesign of the entire production floor. Wilson Case was able to rearrange how equipment and parts fulfillment flowed from end-to-end. Instead of delivering individual part types to stations, parts were kitted to each station ensuring an ample supply flow.
Previously, Wilson case dedicated 10,000 square feet of warehouse space to housing precut foam inserts of varying thicknesses for their shipping cases. A Foam Skiver was purchased as an outcome of the Value Stream. Now the company is cutting their foam to the thickness needed for the individual case. “That has really changed how we design our cases,” said Huffaker. “We no longer think in terms of stock foam sizes; we are able to design and deliver what the individual job requires.” Cutting their own foam also opened up square footage to house inventory of other components.
Results
As a result of the Value Stream Mapping process, Wilson Case reported greater profit, reduced labor time to finished product, lowered inventory foam costs, reclaimed additional workspace which facilitated new product expansion, and improved inventory control.
 | Increased sales: $2 million |
 | Jobs Created: 3 full time and 2-3 temporary positions. |
 | Workplace investments: $160,000 |
