TMAC Helps Local Manufacturer to Increase Production Capacity
Wednesday, November 2, 2011
The Texas Manufacturing Assistance Center (TMAC) team of Kurt Middelkoop and UTA engineering student Smriti Neogi were able to help Hatco make significant improvements to their manufacturing facility in Garland Texas. Hatco is the manufacturer of Stetson, Resistol, and Charlie 1 Horse hats sold throughout the country. TMAC’s Lean principles taught their employees how to spend more time working on the hats and less time moving them through the 150,000 sq. ft. facility.
They were able to increase production capacity by 60 hats per hour which enabled them to increase their headcount and to produce more hats this fall. Hatco employees are now allowed to leave early, with full pay, when production goals have been met. In addition, they can now turn off the lights and boiler early to reduce their utility costs by more than 3%. These savings also helped reduce their impact to the environment and reduce CO2 emissions by more than 189,000 pounds per year.