Revolutionizing Efficiency: Marzilli Machine’s Journey with ProShop Software
James Marzilli, the founder and president of Marzilli Machine, a premier component manufacturer in Fall River, Massachusetts, emphasizes the critical role of waste management in operational efficiency. Despite running his shop since 2011 and implementing an ERP system in 2013, Marzilli found the task of managing operations daunting, resonating with the struggles of many small-scale manufacturing businesses.
Amidst the COVID-19 shutdowns in his state, Marzilli reevaluated his business strategy and stumbled upon an advertisement for ProShop in Modern Machine Shop. Intrigued, he embarked on a trial run with the software, eventually integrating it into his operations within six months. Over the ensuing year, process improvements driven by ProShop propelled Marzilli Machine’s gross revenue by an impressive 64%, affording James Marzilli a moment to breathe away from the shop floor.
Transforming Processes ProShop yielded tangible benefits for Marzilli, primarily in efficiency gains and waste reduction, notably in tooling management. Previously, the shop employed a rudimentary organization method, resulting in unnecessary waste. However, by linking ProShop Tool Manager with Mastercam Tool Library, the shop streamlined its tool digitization process and enhanced coordination between programmers and planners.
Marzilli highlights two ProShop features – Process Development and Shift Tie-In – as pivotal in boosting efficiency. Process Development enables operators to suggest process refinements directly within ProShop, ensuring continuous improvement across repeat orders. Meanwhile, Shift Tie-In facilitates seamless communication between employees across shifts, enhancing collaboration and problem-solving.
Flexibility in Action ProShop’s versatility extends to production planning, empowering Marzilli Machine to optimize its scheduling and resource allocation. Analysis of spindle hours and downtime facilitated strategic workforce allocation, resulting in a 50% reduction in spindle downtime. Additionally, ProShop’s file system enables agile production planning, allowing quick transitions between machines to accommodate shifting production demands.
The Quality Control Paradigm Marzilli’s proactive quality control approach, epitomized by its “War Room” meetings, underscores the shop’s commitment to excellence. These meetings, facilitated by ProShop, enable preemptive problem-solving and foster a culture of continuous improvement. Integrating quality data from High QA into ProShop further enhanced the shop’s quality assurance capabilities, attracting clients with stringent quality requirements.
Rapid Growth Trajectory Embracing ProShop and implementing management changes propelled Marzilli Machine’s rapid growth. In 2021, the shop achieved a remarkable 64% revenue growth without significant capital spending, a trend that continued into 2022 with a 28% revenue increase. Despite space constraints, Marzilli plans to expand into a larger facility, aiming to establish a rapid response center and invest in automation to meet the anticipated surge in demand.
Marzilli’s journey with ProShop exemplifies how technology-driven solutions can revolutionize traditional manufacturing practices, paving the way for unprecedented growth and efficiency gains.
Original source MMS
