Company Profile: Johnson Outdoors, Inc is a world-wide manufacture and distributor of Eureka! camping and commercial tents, Camptrails backpacks, Silva compasses and tents for the U.S. Armed Forces. The regional facility is located in Conklin, N.Y.

Situation: Johnson was in the process of fulfilling a contract with the US Armed Forces for the Modular General Purpose Tent (MGPT) when it became apparent they could not keep up with demand in their existing line, having produced a maximum of 30 tents per week. Having worked with AM&T on quality over the last year, Johnson enlisted AM&T to analyze the MGPT line.

Project: AM&T assigned two consulting staff to begin the analysis process. The existing product flow was mapped, operational data gathered such as rates, equipment data, product types processed. The “as-is” picture was reviewed by key Johnson people for verification. After product and process data was understood, an assessment was conducted focusing on production flow, problems, communication, training and goals. The completed assessment, with AM&T recommendations, was reviewed by Johnson management and participants. A team was formed consisting of operators, management and AM&T staff to address the “to-be” process. Several problem-solving and idea gathering sessions were held. A line analysis was performed to examine operational loads at various volume levels, focusing on equipment loads and requirements. A scheduling spreadsheet was developed to help management and operators with daily requirements of sub-assemblies and finished tents, along with required staffing at each operation. Flow improvements were made within the restrictions of the space available. After several weeks, significant output improvements were realized (20-30%). Realizing the power of using Lean techniques, Johnson decided to make space available that would allow for a totally new line configuration. The team then developed several alternatives, finally settling on one, and the existing line was moved to the new area with a revised flow.

Impacts: After struggling to reach 30 tents per week under the old conditions, output from the new line is currently at 66-70 per week, with minor added staffing. This allowed Johnson to accelerate its delivery against the contract, increasing revenue and cash flow.

Testimonial: “The AM&T team helped us realize the potential of a Lean environment. They did a thorough analysis, worked well with our people, and the results speak for themselves.”

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