In most contract manufacturing environments, efficiency comes from long runs on high-speed equipment. Breaking into the schedule for small volume needs is like asking a busy airport to clear its runways of 747s to make room for small private jets to land. It’s just not realistic.

By contrast, RBB’s shop is more like a merry-go-round at your local amusement park. Each ride is short, so as it spins, an opening is almost always available without a cost penalty. In fact, the occasional large batch is divided into small batches to ensure no job is delayed. Simply put, we’re built for small batches.

A Breakthrough Approach to Lean Manufacturing

RBB uniquely applies lean manufacturing techniques to its recurring small batch, high-mix environment. Constant product changeover means we must get all small batches quickly through the shop. We’ve applied custom lean processes that make our entire facility more efficient, guaranteeing you get your product quickly and cost-effectively.

Additionally, we "swarm" our people and resources to where work is heaviest within our facility—so there’s less time wasted traveling from point A to point B. We also allow ourselves the flexibility to change up “swarming” patterns if we realize additional efficiencies can be gained from reconfiguring. Capacity is further maximized through cross-training and strong internal communication. Here are some figures and facts to give you a better idea of our capacity in relation to team and facility:

  • We operate out of a 20,000-square-foot facility in Wooster, Ohio
  • Work days are scheduled as single-shifts, five days a week (with evenings and Saturdays available as needed)
  • Our cross-trained workforce meets IPC standards
  • Average lead times are eight to nine business days after parts arrive (expediting is possible)
  • Between 180 and 250 small batches are shipped each month

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