1. Campbell Corporation | 7111 W. Edgerton Avenue | Greenfield, WI 53220
Phone: 414.421.7601 www.campbellcorp.net
PROCESS LAYOUT
Earlier this year, Robert Campbell and John
Collins visited our Vacaville, California facility. In
less than a day, they keyed in on our largest
constraint: painting!
By interviewing various members of our team
including our Manager of Engineering, our
Manufacturing Engineers, paint line operators,
and myself, they recommended a combination of
simple solutions which allowed us to increase
throughput by 40% in less than one week. Their
final recommendations, which consisted of
procedural and policy initiatives, increased the
throughput of one of our two paint lines by 215%
allowing us to remove the other paint line
completely and transfer it to one of our other
facilities. This not only freed up about 6,000
square feet of floor space at our Vacaville facility
but saved our other facility the expense of
purchasing a new paint line. Thanks to Campbell
Corporation, in a few short months we went from
having two paint lines which couldn’t keep up
down to one with extra capacity!
Mark Palmatier
Plant Manager
M&G DuraVent
“
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DuraVent Gains 115% Improvement in Paint Line
Efficiency and 22% Improvement in Material
Handling from Proposed Facilities Redesign
DuraVent is a recognized technological leader in the venting industry. Consistently
the first to market with new innovations in venting systems, DuraVent has captured
a leadership position in emerging markets. DuraVent has patents for several
products and continues to design safe and technologically advanced venting. The
company's research into solving problems with corrosion, when biofuels such as
corn are used, led to the break-through patent for PelletVent Pro.
They began working with Campbell Corporation in their Vacaville, California facility
after consolidating two of their manufacturing facilities into one. The company’s
newly combined manufacturing operation had significant challenges with facility
layout, material handling and process flow, which were resulting in late deliveries,
high WIP and inventory levels, and long cycle times.
Just Do It
Campbell Corporation began its preliminary study of the facility and quickly
recommended a list of immediate improvements, called “Just Do Its,” that DuraVent
could implement to resolve significant bottlenecks in its paint line that were a major
cause of late customer deliveries. These recommendations included speeding up
the paint line timing, reducing the space between products on the line and several
other adjustments, which immediately eliminated bottlenecks and even enabled the
company to remove one of the paint lines and use it at another facility. A series of
small changes yielded big results for DuraVent, with a 115 percent improvement in
paint line efficiency.
Digging into the Data
Next, Campbell Corporation tackled the challenge of developing a facility redesign
project with a significant lack of relevant data to aid in decision making. Like many
manufacturing organizations, DuraVent had some production data, but very little
operating time data or standard work diagrams, and was lacking a comprehensive
data collection infrastructure. Working in close collaboration with the DuraVent
team, Campbell Corporation was able to obtain the data needed for the facilities
study through observation and manual data collection to close the gaps between
the data required and the data that was readily available. There also was significant
SKU complexity in DuraVent’s highly complex, high volume product manufacturing
facilities that required a considerable amount of analysis by the Campbell team to
identify potential efficiency gains. As part of its recommendations, the Campbell
manufacturing consulting team outlined a process for DuraVent to enhance the
accuracy and analysis of production data so that future process improvement
projects would be easier.
Streamlining Production
Campbell Corporation generated three different process layout designs to
determine the layout that would achieve the greatest improvements in both material
flow and process equipment efficiencies. The recommended layout design required
an implementation budget of $1.15 million that would yield a return on investment
in approximately 1.68 years, and the project would be completed in 13 months
without impacting production.
Campbell also made recommendations that could be implemented while the basic
process layout was being reconfigured in order to gain efficiencies throughout the
13-month transition. In addition, DuraVent was advised to incorporate Campbell’s
Lean manufacturing culture within the plant to teach all personnel to identify and
eliminate waste in the production process. Implementation of an ERP system was
also recommended to ensure more reliable manufacturing schedules.

2. Campbell Corporation | 7111 W. Edgerton Avenue | Greenfield, WI 53220
Phone: 414.421.7601 www.campbellcorp.net
Campbell Corporation is a Lean process and facilities design consulting firm based in the United States
with extensive global experience. We are a recognized leader and innovator delivering a demonstrated
approach to process improvement and facility design across countless industries. Campbell
Corporation’s client base ranges from small single shop manufacturers to Fortune 100 Manufacturers
with multiple facilities throughout the world.
Campbell Corporation’s suite of services includes Lean Six Sigma consulting, facility design focused on
supporting Lean processes, enterprise wide strategic production planning, and project execution.
Our approach is focused on utilizing Lean principles to perfect the processes which transform raw
materials to finished goods resulting in improved operational performance. We utilize a balanced
strategy of intense project management and the blending of resources, technology, experience, and
expertise to achieve sustainable solutions to our clients’ unique challenges.
Our facility design professionals work hand in hand with our expert Lean Practitioners to design an
optimized process layout to fit within an existing facility or to design a new facility which completely
support Lean operations.
Whether implementing or improving a Lean transformation, developing a new facility or adding onto an
existing one; Campbell Corporation’s proven results oriented methodologies can lower costs, waste,
WIP, finished goods and man hours while increasing efficiency, quality, and overall ROI.
Sectors Team Clients
Our manufacturing and
business process experience
includes Machinery,
Fabrication, Electonics,
Petroleum, Textile, Wood,
Printing and many others
Our Team of 50+ executives,
designers, and lean professionals
provide our clients a scallable,
diverse and experienced resource
to tackle any problem in any
industry
Our clients and projects range
from Fortune 500 companies to
family owned manufacturers with
projects ranging from Kaizen
events to Global Enterprise
Solutions
Efficiency and Lower Cost
With Campbell Corporation’s assistance, DuraVent will reap significant improvement to their operational equipment efficiency, and
improve overall material handling by 22 percent. The total production efficiency will improve 26.4 percent when the implementation
is complete, including a 20 percent improvement in press operations efficiency and a 12 percent increase in packaging operations
efficiency. The efficiencies are so significant that the company is gaining 25.5 percent more production space availability, enabling
them to consolidate other product manufacturing into the same plant, further improving the efficiency of their national supply chain.
Campbell Corporation’s ability to analyze and understand DuraVent’s highly complex product matrix and manufacturing
requirements, combined with the firm’s significant experience in manufacturing facility design and process improvement, is enabling
the team to deliver a plant redesign that offers greater efficiency and better material flow at a lower cost. By offering additional
recommendations that could be implemented at the beginning of the project, as well as during the transition period, Campbell
provided added value every step of the way to enable the DuraVent team to recognize the progress they are making throughout the
redesign process.