The Extension Connection
Above: Using CIRAS simulations, the Mastercraft factory was relocated in a smaller building with improved product workflow. Below: As part of the move, CIRAS redesigned the out-dated belt and pulley system on the steel equipment and created new drives mounted directly on each machine.
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Last update: July 2003
A quarterly publication of Iowa State University Extension
Industrial specialists are partners in Mastercraft relocation
When Barry and James Nadler bought the Omaha Mastercraft
sofa and chair manufacturing plant last year, they sensed product flow
and layout inefficiencies in the antiquated facility. Wanting to improve
the situation, they contacted local resources to determine the changes
that would solve their production challenges.
Barry Nadler’s first contact, Council Bluffs Chamber of Commerce
business development director Mark Norman, connected him with Clay Crandall,
Iowa State University Extension industrial specialist and Mark Stanley,
Iowa Western Community College executive director of business and industry.
Crandall, of ISU Extension’s Center
for Industrial Research and Service (CIRAS), Stanley and Iowa
Manufacturing Extension Partnership (IMEP) account managers Don Reiner
and Robert Coacher began developing a plan for Nadler.
Five months after that first contact, the Omaha facility had been evaluated
and a new one planned, financed and built in Council Bluffs.
“We took a 130,000 square-foot production operation and moved it
into a new 66,000 square-foot facility,” Nadler said. “One of
the first things we did was determine if it would fit in a smaller building.”
Crandall and CIRAS industrial specialist John Van Engelenhoven helped
make that determination through a plant simulation and layout process.
“We moved equipment around in the old facility until we had a reasonable
layout,” Nadler said. “The CIRAS specialists developed a base-line
model for utilizing labor, space and improved product flow, then presented
us with five different layout designs and we decided which one would work
the best for us.”
The selected layout was mapped out in the new building, with each piece
of equipment being moved onto an exact destination. The precision of the
plan shortened the time it took to relocate.
“Within two weeks we were moved and up and running at the Council
Bluffs location,” Nadler said. “Crandall did a great job giving
us hands-on assistance in re-fitting the machinery to fit the new location
and keeping our down time at a minimum.”
Council Bluffs Chamber executive Norman said, “When Barry visited
with me about wanting a new facility and improved efficiencies, I knew
we needed to get in touch with CIRAS, IMEP and the community college.
This was a very fast track project that has added to the tax base through
the new construction, added 45 jobs and potentially may add up to 100
jobs, and is a great addition to our business community.”
Stanley at Iowa Western Community College is pleased to be part of Mastercraft’s
relocation to the community and looks forward to providing continued education
to the employees.
“We will be issuing bonds on behalf of the company that allow us
to provide instructional training to the employees,” Stanley said.
“There are many topics that could be included in that training, from
LEAN manufacturing principles to language training. We will be working
with the owners to develop an employee training plan.”
The partnering resources — CIRAS, IMEP, IWCC and the Chamber —
say that the Mastercraft relocation, while higher impact than their average
projects, is typical of the work they do with business and industry in
Iowa. Nadler says that having his new factory up and running, and running
fairly efficiently, within four months is no small feat.