Case Studies
CUSTOM TOOL AND MODEL CORPORATION
CTM Corp. is a high-precision machine shop that can design and manufacture products from prototype to production. CTM Corp. provides top-quality work and services to the Aerospace, DoD, Medical, and Firearms Industries. They are located in Frankfort, NY and employ 19 highly-skilled employees.
Challenge
CTM Corp. has to comply with both ISO and Cybersecurity certifications and requirements to comply with DoD and Aerospace contracts. In order to retain business and bid on new contracts within the industries, CTM had to implement and train their employees in both quality and Cybersecurity standards.
Solution
The Advanced Institute for Manufacturing will provide Quality Management Systems (QMS) training to meet industry standards. AIM has also provided Cybersecurity assessments and employee training to meet DFARS requirements.
Results
CTM is currently ISO 9001, AS 9100, ITAR certified, and DFARS compliant for Cybersecurity. Certifications in these areas help CTM retain contracts as well as bid on new business in the future within the Aerospace, Medical, and Firearms industries.
“We count on AIM and their resources”
"CTM, as a small business, relies on AIM's organization to pivot to changing markets. Training grant opportunities, cyber security upgrades, or basic quality management support, we count on AIM and their resources."
STEVEN NAEGELE - CTM Corp., President
"We have found every experience to be enlightening, engaging and effective."
"The FX Matt Brewery has partnered with multiple branches of AIM/MVCC and their respective trainers, consultants, teachers, training centers and MEP center. We have found every experience to be enlightening, engaging and effective. Their team is high performing, knowledgeable and most importantly responsive and adaptive to meeting our needs. I look forward to continued partnership and meeting our future needs"
DAN VOCE - FX Matt Brewery, Director of Operations
Matt Brewing Company
Matt Brewing Company was founded in 1888 under the name The West End Brewing Company. It is the fourth oldest family-owned brewery in the United States, having brewed beer since its inception. The brewery, later renamed Matt Brewing Company, became popular throughout the Northeast based on Utica Club and its current flagship beer, Saranac. In addition to beer, Matt Brewery also distributes popular soft drinks, notably the Saranac 1888 Root Beer. The Company is in its fourth generation of family ownership and is led by Nick Matt, Chairman and CEO and Fred Matt, President.
Challenge
Matt Brewing Company had a need for updated SOP’s to enhance employee’s skills and training. They decided to invest in having new SOP’s created and reached out to AIM for expertise in quality technical resources and creation of employee job instructions.
Solution
AIM conducted onsite facility visits to observe, document, and collect data to create SOP’s and checklists for each job process. Each newly created SOP and checklist outlined major steps, how to instructions, key points for safety, and visuals of each operating procedure.
Results
The modernized SOP’s and checklists create a culture of consistency and repeatability along manufacturing processes as well as increased employee skill sets and knowledge.
MHX Co Foam Company LLC
MHX Co Foam is a privately held company in Amsterdam, NY they specialize in foam manufacturing. They sell a wide variety of foam forms and serve various industries. MHX Co Foam is currently ISO 9001: 2015 certified and manufactures four major foam products.
Challenge
As manufacturing business rebounds from the pandemic, this past year MHX Co has been hiring more machine operators. Like many manufactures, they are facing challenges finding qualified manufacturing workers. New machine operators were recently hired and the workers primary language is Spanish, which will require additional support to learn the jobs. The company has an opportunity to address recurring quality problems and productivity with enhanced operating procedures, detailed work instructions and formalized employee training.
Solution
The Advanced Institute for Manufacturing will work with MHX Co to create Standard Operating Procedures (SOP) and work instructions (WI) that will guide new employees through successful training and equipment operation. Leads and job coaches will utilize the newly created SOP’s and WI to develop machine operators. AIM will also provide translation services for the Spanish speaking employees that will take place in a formal training program.
Results
SOP’S and Work Instructions have been created in both the English and Spanish language. Together, they will work to support employee training, increase productivity and efficiency, and support ISO certification. The program allows the company to provide new operators with formal training and a system to test for comprehension and proficiency once thoroughly trained.
“AIM has been a game changer for our business”
"AIM has been a game changer for our business. Working in collaborative partnership, AIM delivered a high-quality training program that was tailored just for us. The training has already made a positive difference in our quality and our bottom line.”
PETRA SCHAEFER - President & Owner, MHX Co. Foam Company, LLC.
"Workshops for Wolfspeed Equipment Technicians develops core skills contributing to a successful workforce."
"Mohawk Valley Community College workshops for Wolfspeed Equipment Technicians develops core skills contributing to a successful workforce. The location of the college in the Mohawk Valley, benefits students and Wolfspeed to offer opportunities and contribute to the community.”
ERIC CLARK - Equipment Engineering Manager, Mohawk Valley Fab
Wolfspeed, Inc.
Wolfspeed Inc. is a developer of wide bandgap semiconductors, focused on silicon carbide and gallium nitride materials and devices for power and radio frequency applications such as transportation, power supplies, power inverters, and wireless systems. The company, formally known as Cree, was founded in Durham, North Carolina and is currently in the process of finishing up construction on their Silicone Carbide Facility in Marcy, NY.
Challenge
Wolfspeed is in the process of completing construction of their new Silicon Carbide facility in Marcy, New York. The next step is to hire highly skilled employees to operate the facility. The skills necessary to operate the plant are very specific to this facility and the type of equipment used. The challenge is that there are very few potential employees that currently have the specific skills needed and there is a strong demand to hire approximately 600 employees in the first five years of operation. The semiconductor and micro-electronics industry are new to the Mohawk Valley Region, and it is extremely important to build the local workforce that can support Wolfspeed and the entire industry.
Solution
AIM has used its position as an MEP Center component of Mohawk Valley Community College and its 75-year history as a technical college to connect with its resources and local expertise to develop a customized training program that is recurring as Wolfspeed hires new employees and as they open the doors to the new chip fabrication facility.
Results
The 10-day, 13-module “hands on” training program was launched in the fall of 2021 and continues to be provided on demand as Wolfspeed grows in the Mohawk Valley Region. The class participants will acquire a learned skill that enables them to operate, troubleshoot, and problem solve electrical systems, mechanical systems, tooling and calibration, helium leak detection equipment, and vacuum systems. All these key skills are required to work in the micro-electronics industry.
Utica Coffee Roasting Co.
Utica Coffee Roasting Company (“Utica Coffee”) began in 2002 manufacturing roasted coffee beans for the retail and wholesale market. Located in Utica New York, they practice current, sustainable, and renewable business practices, hire local, and sell local to central New York.
Challenge
Utica Coffee has requested the services of Advanced Institute for Manufacturing (“AIM”) to observe and assess the warehouse operation for improvement and provide the necessary employee training for a lean culture and sustainability. A primary focus will be on the warehousing delivery and storage of its products. Being new to many aspects of the business Utica Coffee instilled confidence in the AIM team to advise, train and guide them to the right practices.
Solution
Upon assessment AIM’s primary focus was to improve Utica Coffee’s warehouse and order fulfillment by addressing areas of process improvement, recommendations for facility layout and extensive training by industry expert’s such as Lean Six Sigma Yellow Belt Training.
Results
As a result of the training that AIM and industry experts provided Utica Coffee, they now have developed a safer work place that has provided their employees with training, which has led to measurable quality and process improvements throughout the company. The improvements have impacted the company’s bottom line, and has engaged the employees with meaningful and impactful work.
“AIM provided Utica Coffee Roasting Company the opportunity to thrive ”
"The AIM program provided Utica Coffee Roasting Company the opportunity to thrive by adapting new and innovated training processes that can bring more success to the organization for years to come.”
FRANK ELIAS - President, Utica Coffee Roasting Co.
"When a company grows at this rate it is important to have people who are educated in the areas of need."
“When a company grows at this rate it is important to have people who are educated in the areas of need. Production activity is being moved from one building to another.”-
ERIC CLARK - Equipment Engineering Manager, Mohawk Valley Fab
Indium Corporation
Indium Corporation also known as “Indium” is a premier developer, manufacturer and global supplier of indium, indium compounds, and various products based on other metals. The company has global technical support and factories throughout China, India, Malaysia, Singapore, South Korea, the United Kingdom, and the USA.
Challenge
With Indium Corporation growing at rapid speeds around the world it was identified that the company must comply with multiple training and development tools and certifications. Indium requested the services of the Advanced Institute for Manufacturing (AIM) to provide Lean Six Sigma Green Belt Training. The Intent of the program was to drive the employees at Indium to have more detailed experience.
Solution
An Enterprise resource plan was designed to fit 500 people, along with a plant wide Kaizen event. Andy was able to help Indium reorganize the entire company floor plan by creating factory wide diagrams. As a result, Indium can continue to produce products to fit customers’ needs at a higher volume with a shorter delivery time.
Results
AIM’s Senior Manufacturing Consultant, Andew Longway, instructed an eight-day workshop combined with comprehensive classroom training . In this workshop, AIM introduced the basic concepts of Lean Six Sigma and demonstrated the tools and methodology necessary to successfully apply them within the DMAIC process improvement framework.
Custom Electronics Inc.
CEI, established in 1964, is a globally recognized manufacturer of top quality mica paper capacitors and tailored high-voltage assemblies. Located in Oneonta NY, their products are widely used throughout the military, commercial and industrial markets.
Challenge
As a defense manufacturer Custom Electronics, must comply with both ISO and Cybersecurity certifications and requirements to comply with DoD and Aerospace contracts.
Solution
The Advanced Institute for Manufacturing provided NIST SP 800-171 Cybersecurity assessments and employee training to meet industry standards.
Results
Custom Electronics Inc. is currently ISO 9001, AS 9100, and DFARS compliant for Cybersecurity. Certifications in these areas help Custom Electronics retain contracts as well as bid on new business in the future.
"AIM has been a great resource for HPK..."
"AIM has been a great resource for HPK and stepped up to assist HPK as the company expanded operations as a result of the increased demand for HPK USA made PPE due the COVID 19 Pandemic."
MIKE LIBERATORE - President
HPK Industries
HPK Industries is a state-of-the-art manufacturer, specializing in Medical, Biotech, Pharmaceutical, Cleanroom, Laboratory, and Industrial personal protection equipment. HPK currently employs more than 50 employees at their facility in the Herkimer County Industrial Park. HPK’s products consists of coveralls, shoe covers, arm sleeves, aprons, face masks, and additional products for sterile environments.
Challenge
HPK was approached by its largest client for an opportunity to increase the volume of business and the requirement to have a registered Quality Management System to ISO 14385 Medical Devices – Quality Management System. As a result, HPK Industries needs a comprehensive Quality Management System to ensure quality standards, customer compliancy, production efficiencies, and employee safety.
Solution
Mike Marusic, AIM’s SR. Manufacturing Consultant was able to conduct a quality assessment that identified areas that needed adjustment. A quality manual was developed to fit the needs of HPK to perform work at the highest performance. AIM has been tasked to guide and help the company create the necessary structure, create procedures and documentation, as well as to train HPK on the Medical Industry required compliance standard.
Results
At the completion of this project, HPK will have the tools and knowledge to grow its business and market its products as being produced within the industry as being a certified QMS manufacturer of Lab Disposable PPE.