INSIGHTS
12/20/2024

Applied Fabricators sharpens competitive edge with LEAN Sheet Metal Storage Racks

Jordan Meyer, PMP, CPIM

A Growing Industry Leader in Cold Storage Manufacturing

Applied Fabricators, a family-owned business located in Greenfield, Indiana, was founded in 1984 by Bob and Julie Reeve. 

Specializing in fabricating metal for the cold storage construction industry, they produce a variety of products, including heavy gauge angles, tracks, channels, door opening wraps, and embossed metal trims. They also fabricate commercial roof edges such as coping, fascia, drip edge, gutter, and downspout. 

The company is currently owned by their son, Brandon Reeve, who took over in 2008, and prides itself on its rapid response to customer needs and its ability to handle both large and small orders efficiently.

With significant growth over the years, Applied Fabricators has diversified into other industries and implemented automation and innovation to enhance their operations. 

Recognizing the need to utilize their existing facility space more efficiently, they formed a partnership with our team at Lean Manufacturing Products. This collaboration began with an in-depth review of Applied Fabricators' current operations and material storage methods.

The facility before LEAN Sheet Metal Storage Racks

Although their materials were off the ground, accessibility and organization needed significant improvement. 

Applied Fabricators used cantilever-style racking to stack their material pallets in the same manner they received them. However, with limited space left in their cantilever racking and the inability to stack more pallets due to tight spacing, they had no choice but to place the excess materials on the floor. 

As they consumed the material, they were left with the removal and disposal of the wooden pallets, which in some cases remained in their racking without any material, taking up valuable storage space.

The challenge in accessing their materials prompted a call to action to replace their current storage methods.

Material Consolidation After Metal Storage Rack Implementation

Through continuous discussions and collaboration, our team tailored a material storage solution to their exact needs. 

Their LEAN Safety Block Storage Systems were implemented to consolidate materials and create more space on the shop floor. 

As a result, significant space savings and streamlined access to materials were immediately noticed, leading to cost savings throughout Applied Fabricators' entire supply chain. Brandon Reeve, owner of Applied Fabricators, stated that:

"the new Lean racking system has improved workflow significantly. The cartridges has allowed AFAB to separate all colors and materials into separate cartridges; making it much easier to find and access materials quickly. Within minutes we can pull out a material selection and begin fabrication. Previously with our cantilever racks, because of the limited number of shelves we often stacked multiple materials on the same skid. One lean rack took the place of 3-4 cantilever racks, which helped tremendously!" 

The enhanced efficiency and optimized space utilization have strengthened Applied Fabricators' competitive edge in the fabrication industry and they now have a seamless process for accessing the exact material they need and directing it straight into their laser and downstream operations. "It helps our production efficiencies and our quality control" stated Brandon. "With materials separated on individual cartridges, there is much less risk of mistakes of grabbing the incorrect materials". With AFAB's recent expansion to their facility they were able to add automated machinery while consolidating their material storage with the integration of Lean Storage Systems. Brandon Reeve stated "We have brought on financial advisors, and they have been showing us dollar values of square footage, and how valuable the space is. We cannot add on to our building anymore, we are on the edge of our property line now.  We need to maximize our space, and the Lean storage racks have been one of the best innovations that help us do this!".

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Begin Your Own Lean Manufacturing Transformation

If you have outdated sheet metal storage methods and are looking for high-quality solutions, learn more about our Sheet Metal Storage Racks here.

To view the entirety of our product portfolio, visit our products page here.

If you have further questions, get in touch via email at info@leanmfgproducts.com or give us a call at 262-875-3071

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