PLZ Aeroscience commemorated its new Global Distribution Center Gaus with a ribbon cutting on Dec. 15, 2015. From left to right: Rick Dames, industrial realtor firm Cressa; Chris Schmidt, Cressa; Nathan Wirth, Brinkmann Constructors; John Ferring, PLZ Chairman; Dave Klug, Brinkmann; Jeff Palmore, Mayor of Pacific, MO; Harry Engelhart, neighboring farmer & former landowner; and Geoff Ladue, PLZ COO. “What’s most remarkable about this milestone is the time in which it took us to achieve it,” Ladue stated. “Our one billion can milestone was reached in a period of aerosol production that took place from 1948 to 2010— evidence of a 62-year commitment to excellence…we were able to achieve the two billon can milestone in just five short years. We are extremely proud of this accomplishment and wish to thank our customers and the many individuals, the dedicated employees of PLZ Aeroscience, who ‘make it happen’ every single day.” 16 Spray March 2016 Precise adds powder aerosol capacity Precise Packaging of Fall River, MA continues to grow in 2016. “We continue to add capabilities and expertise in support of our mission to be a full-service product development and manufacturing partner to our customers,” explained Precise Packaging CEO Shaun Gaus. “This includes additional capacity for powder aerosols and the installation of a specialty liquid filling line, along with a newly renovated office space and expanded product development laboratory,” Gaus added. “We also strengthened our team with key hires in the areas of product development, production planning and scheduling, customer service and new business development.” FAREVA transforms warehouse to manufacturing plant FAREVA recently completed a major investment project at its U.S. facility in Richmond, VA by transforming warehouse space into a 50,000 sq ft manufacturing facility, capable of producing 100 million aerosol units per year with possible increase. The first production of this good manufacturing practices (GMP) facility was completed in December 2015. The site is led by Richard Hayes, Site General Manager and the aerosol operation is led by Steve Doble, Director of Aerosol Manufacturing. Aerosol manufacturing technology provides a wide range of new product manufacturing and filling capability for FAREVA USA that includes dry shampoo, hair rejuvenation, hair styling, sun care, AP/Deo sprays, facial mists and body spray. This technology expands the product Aerofil explains Lean Practices In 2007, Aerofil adopted the Lean Practices of the Toyota Production System. It then began to implement Supermarkets (pull-systems) throughout the entire supply chain. Using proprietary software developed internally by the Aerofil Lean Dept., Aerofil uses customer data, taking into account multiple factors and variations, to establish the ideal Supermarket levels. The levels are then set-up to support weekly production runs based on actual customer shipments out of its distribution centers to major marketers across North America. Aerofil then works with the customer to set-up a daily automated signal showing actual sales and shipments from the customer’s distribution center. Once the Customer Supermarket sizes are established, Aerofil works with suppliers to establish internal material Supermarkets within Aerofil, as well as within the suppliers’ facilities. These component Supermarkets are sized to support weekly production. To start the process, Aerofil receives a daily signal from their customer’s distribution center, then populates a Heijunka Box (level loading scheduling tool), which is used to schedule the production lines. The Heijunka device is a representation of their customer’s actual inventory levels in their distribution centers. Aerofil then schedules its production lines based off of which items have the lowest amount of inventory. When it is time for production of that product, it pulls materials out of its internal Supermarkets to support production and a signal is sent to the suppliers to replenish what was used at Aerofil. Once the supplier sends in the materials to replenish what was used, it goes into production to re-stock the Supermarket at its facility. Advantages to Supermarkets include production based on consumption, not forecast; lead times are reduced from weeks to days; dramatic reductions in inventory-carrying costs; improved fill rates; increased inventory turns and substantial cost savings. According to Aerofil, this is not an inventory control system, but rather a scheduling system that tells what to produce, when to produce it and how much to produce. Since 2009, Aerofil has saved customers in excess of $10 million by implementing the Supermarket process, according to the company. Aerofil Heijunka Box
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