Company
Clarke Communications is a medium volume commercial printer located in Lynchburg, VA employing 15. The company itself has been in operation since 1955, but was purchased six years ago by Victor and Robin Clarke. The Clarkes are the owners and chief operators of the printing facility. The organization prides itself on providing quality printing via referral relationships with customers. This philosophy has won them a majority of jobs.

Situation
The presence of GENEDGE ALLIANCE in the printing plant is nothing new to the Clarkes. GENEDGE ALLIANCE has a relationship with Clarke Communications dating back to 1998. The most recent endeavor, Value Stream Mapping, identified non-value added activities for elimination and to improve operations by streamlining the information flow. The Clarkes were now ready to take their operations to the next level through Lean Implementation with GENEDGE ALLIANCE's assistance.

Response
The overall objective was to improve printing operations and to strengthen first time quality. Streamlining the information and material flows process will provide the means for transitioning from their Current State Value Stream to a Future State Value Stream. This should reduce current lead times, reduce resource requirements, while improving quality and ability to meet demands for shorter turn around.

Steve Nattsas, GENEDGE ALLIANCE Project Manager, then led the education of Clarke Communications' personnel in the theory and practical application of Cellular Flow/Manufacturing, and other Lean manufacturing techniques. The same personnel then moved on to the design and implementation of a customer service/pre-press processing cell, and other process improvements to be developed. This ongoing process would last approximately six months.

Results
Overall operational performance has been greatly improved as reflected in the following:
• Paper inventories reduced by 60%
• Lead time reduced by 50%
• Profits are up for the same time period even though revenues are down from prior year’s figures
• Estimated that 5 jobs were retained as a result in the change of operations
• Quality levels greatly improved
• Print shop working conditions and employee morale have improved
• Management made a capital investment in new digital pre-press equipment based upon Value Stream Analysis

Testimonial
"GENEDGE ALLIANCE and all its employees are knowledgeable and take their roles as a technical resource very professionally, seriously and with integrity. I highly encourage other manufacturers to take advantage of GENEDGE ALLIANCE too!"
-Victor Clarke, President

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