Lean Leads to Significant Production Efficiency Increase

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"Thanks to CONNSTEP we’re not wasting or scrapping. We’re working smarter and more efficiently which leads to greater savings that are shared with all employees. It’s a win-win situation for our company and employees, and for our customers. We’re able to ship a quality product and fulfill our mission of providing the ultimate customer experience."

Jerry Russo, Senior VP of Operations, Prime Line®


Prime Line® has been a leading supplier in the promotional product industry since 1980, offering more than 1,600 items in 15 product categories. Its products are sold primarily in North America through a network of distributors.


The company markets promotional items such as bags, drinkware, writing instruments, apparel, stationery, gift sets, novelties, and more. In 2017, the company merged with alphabroder, the largest supplier of imprintable apparel in North America.

  • Challenge

    Prime’s business was surging and it was necessary for the company to improve the productivity of its pad printing department. Printing is a key form of revenue for the company and they wanted to grow without having to buy new machines or needing to hire more people.


    Their goal was to increase efficiency by a minimum of 10%. Prime Line® turned to CONNSTEP, who they had worked with in the past, for training in Lean manufacturing tools and techniques to help reach their goal.

  • Solution

    CONNSTEP met with the Prime Line® production team, reviewing the challenges they faced on a daily basis in the pad printing area, such as reducing machine downtime for improved productivity. Also, they expressed their desire for greater employee engagement in the production process for better company morale.


    After initiating a Value Stream Mapping process and identifying areas of waste, the CONNSTEP team worked with key Prime Line employees on set-up reduction to help reduce the amount of downtime between production runs. CONNSTEP also introduced 5S to the production area for a less cluttered, more organized workplace and to be better prepared for next-in-line orders.

  • Result

    Applying set-up reduction to the pad printing process at Prime Line® resulted in reduced machine downtime, less material waste, fewer defects, and higher productivity. The ink, fixture and piece were ready to go, executing next-in-line orders more efficiently. The process was complimented by a 5S program that put materials in the right order for production purposes.


    An incremental benefit was increased employee engagement and higher morale due to a sense of participation in and ownership of the new production process. Many solutions came from group leaders in different departments.


    Prime Line exceeded their initial goal by increasing efficiency nearly 15%, turning out more products per day to meet their increased business demands.

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Project Impact

$185,000 New or Retained Sales

$155,000 Cost Savings

37 New & Retained Jobs

April 29, 2026
Phoenix Manufacturing, Inc., founded in 1989, is a privately held family-operated small business in Enfield, Connecticut, specializing in precision machining for the aerospace industry. What began as a two-person operation in a 2,000-square-foot building has grown into a company with over 100 employees operating out of a 114,000-square-foot, state-of-the-art manufacturing facility. As a contract manufacturer, Phoenix specializes in complex, tight-tolerance components, supported by more than 40 CNC machines and a multi-axis mill/turn line. The company provides end-to-end manufacturing solutions—from engineering consultation through full-scale production—serving commercial aviation, spaceflight, and defense markets for both domestic and global customers, including leading aerospace and defense OEMs. A defining element of Phoenix’s growth has been its strategic investment in advanced manufacturing technology, particularly palletized machining centers. Since 2017, the company has added 11 machining centers integrated with palletized systems, enabling unattended, automated production and significantly expanding machining capacity. This automation journey has positioned Phoenix to better meet increasing customer demand while maximizing machine utilization. Phoenix’s commitment to quality is central to its operations and customer relationships. Managing more than 600 active part numbers, the company strives for 0 parts per million (PPM) defects and 99% on-time delivery (OTD) for major OEM customers. Its quality management system is certified to ISO 9001 and AS9100 Rev D standards, and Phoenix also holds NADCAP certifications in Nonconventional Machining and Nondestructive Testing, reflecting a rigorous, inspection-driven approach to delivering consistent, high-quality results.  Guided by a mission to deliver high-quality, cost-effective products through advanced technology and an uncompromising commitment to quality, Phoenix continues to invest in innovation, automation, and the next generation of manufacturing leadership.
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Founded in 1959, Projects Inc. is a Glastonbury, Connecticut-based manufacturer specializing in precision-machined components for aerospace, industrial, and commercial applications. With 102 employees, the company operates out of 66,000 square feet of manufacturing and office space and supports customers across a range of industries, including aerospace and power generation. Projects Inc. has deep roots in the aerospace industry, where it has provided high-quality machining services for decades. Since 1996, the company has supplied FAA Parts Manufacturer Approval (PMA) components to the aviation sector. Projects Inc. received FAA Repair Station Certification in 1984. As a maintenance, repair, and overhaul (MRO) provider, Projects supports customers with repair solutions that help keep critical aerospace equipment operating safely and efficiently. Its customer base includes major aerospace companies such as Sikorsky, Pratt & Whitney, and GE Aerospace, along with airlines including United, Delta, American, and Lufthansa. Projects Inc. is Federal Aviation Administration (FAA), European Union Aviation Safety Agency (EASA), and UK Civil Aviation Authority (CAA) – approved. The company is also AS9100D and ISO 9001: 2015-certified, reflecting its commitment to quality, consistency, and industry standards. With capabilities that include prototyping, CNC machining, EDM, laser cutting, and grinding, Projects Inc. offers a broad range of precision manufacturing services supported by advanced in-house equipment and technical expertise. Today, Projects Inc. is recognized as an experienced supplier of high-quality components, with a long-standing focus on quality, reliability, and customer service.
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