Lean Manufacturing Improvements Result in Productivity Gains

Logo for Industrial Heater Corp.: text within a box with an electrical element,

"We found the value stream mapping exercise very beneficial, putting pen to paper to quantify processes, evaluating them with actions to tackle them, and giving us a fresh approach."

—Tom McGwire, Vice President, Business Development, Industrial Heater Corp.


Industrial Heater Corporation (IHCO) designs and manufactures a wide variety of standard and custom heaters for industrial processing applications. An ISO-certified company known for their development and production of Band Heaters, IHCO has nearly 100 years of experience in the manufacturing industry with an exemplary international reputation.


A recognized leader in the process heating industry, the company is advancing its business with innovative design and quality products that build customer confidence and success. 


IHCO has built its success by working with companies of all sizes and responding to customers’ needs by helping to keep their machines running smoothly and at optimum production levels.


Given the high cost of energy throughout the world, IHCO seeks to help their customers across many industries to control and reduce these costs in their operations. From Cartridge heaters to Autoclave Furnaces, IHCO products meet the needs for industrial processing.

  • Challenge

    Industrial Heater had worked diligently over the years to build a reputation for producing reliable, quality products backed by solid customer service and on-time deliveries.


    Recently the company was experiencing longer lead times and delayed shipping. In addition, they were beginning to see a decline in information flow, excessive travel within office processes, and a lack of clear visibility to production requirements. All of which were increasing costs and inefficiencies.


    As a result of these new developments, IHCO became interested in improving the productivity of their Mica and Sheet Metal (Hi-Tech) order fulfillment processes. Company leadership was well aware of the benefits of Lean manufacturing tools and techniques having previously participated in CONNSTEP’s Continuous Improvement Champion Certification program.


    IHCO was seeking to use their knowledge of the value of Lean continuous improvement to achieve productively gains in their order fulfillment processes and contacted CONNSTEP for assistance in reaching their goals.

  • Solution

    A CONNSTEP continuous improvement consultant met with the Industrial Heater team to review their challenges and discuss their goals and conducted a comprehensive process assessment of IHCO’s Mica and Sheet Metal (Hi-Tech) order fulfillment processes. The project was designated as a Process Reengineering for Increased Manufacturing Efficiency (PRIME) event funded by the local electric utility Eversource with execution and implementation by CONNSTEP.


    The assessment process identified opportunities intended to have a positive impact on streamlining information and material flow with the Mica and Sheet Metal value streams.


    Lean tools and techniques were taught to many of the IHCO workforce, introducing them to Kaizens, Standardized Work, 5S Visual Workplace, Kanban stations, and the overall benefits of streamlining product flow and eliminating or reducing waste.


    CONNSTEP documented and measured the current state of the Mica and Sheet Metal process value stream. They also identified improvement opportunities towards building a future state value stream for each process with less waste and prepared an action plan to realize the future states.


    Kaizen objectives for the Mica cell and Sheet Metal cell included:

    • Create capacity to increase the overall output of the value stream
    • Improve information and material flow
    • Reduce overall lead time and cycle time
    • Improve the First Pass Throughput Rate within material flow
  • Result

    CONNSTEP assessed the current situation and identified common problems being experienced by Industrial Heater for both their Mica cell and Sheet Metal cell:


    • Completeness and Accuracy issues with incoming purchase orders
    • (Mica) and Request for Quotes (Sheet Metal)
    • Excessive Work in Process throughout the value stream resulting in longer lead times
    • Lack of workplace organization
    • Lack of alignment on multi-line orders resulting in delayed shipments
    • Excessive travel and wait time among process steps
    • Lack of clear visibility to production requirements

    The kaizen resulted in the following improvements for each cell:


    Mica Cell

    • Number of process steps within the value stream decreased from 40 to 25
    • Average Total Lead Time decreased from 18 to 8 days per order
    • Average Total Process Time decreased from 126 to 76 minutes per order
    • First Pass Throughput Rate per order increased from 1% to 25% and continues to improve
    • Average Total Distance per order decreased from 754 to 574 feet

    Sheet Metal (Hi-Tech) Cell

    • Number of high-level process steps within the value stream decreased from 13 to 11
    • Total Production Lead Time (Quoting to Shipping) decreased from 53 to 37 days per order
    • Total Production Lead Time from Engineering to Quality Control decreased from 21 to 8 days per order
    • Average Travel Distance per order decreased from 2,050 to 1,650 feet
Blue circle with white arrow pointing upward, in an orange circle.

Project Impact

$50,000 Cost Savings

$20,000 Retained Sales

$15,000 Increased Investments

4 Retained Jobs

Logos of State of Connecticut Governor's office and RAISE US
By Amanda Beaulieu June 29, 2026
Connecticut is one of several states partnering with a new nonprofit organization to help workers thrive in an AI world and support job growth in the new tech economy. On Monday, Governor Ned Lamont announced that Connecticut is joining Arkansas, Maryland, and Utah in partnership with RAISE US , an organization bringing together states, employers, workers, and educators to build a workforce infrastructure that supports and trains workers to succeed in a future shaped by AI and emerging technologies. “We need to ensure that Connecticut workers and Connecticut jobs benefit from these breakthroughs and do not get left behind,” said Lamont . In May, Lamont signed legislation to help prepare Connecticut’s workforce with the developing technical skills related to AI by establishing new training programs. “Through this partnership with RAISE US, we are committing to take practical next steps to ensure our state has the policies, coalitions, and resources in place to help workers gain new skills, support families through periods of change, and connect people to growing careers,” said Lamont. RAISE US was co-founded by former U.S. Secretary of Commerce and former Governor of Rhode Island, Gina Raimondo, and former Indiana Governor, Eric Holcomb, the co-chair of the organization’s board of directors. According to a press release from Lamont’s office, RAISE US recognizes that emerging technologies are reshaping the economy and require a collaborative approach that brings together state partners, employers, education and training providers, and innovative public policy. “America has a technology strategy for leading the global AI competition. It does not yet have a people strategy—and we cannot lead without one,” Raimondo said. “If we build the best AI systems in the world and leave millions of Americans behind, we won’t have won anything.” Raimondo acknowledged that while AI will create new jobs and industries, it could also bring significant workforce disruption. The RAISE US website cites projections that AI will create a net 78 million new jobs worldwide by 2030, and that workers with AI skills earn, on average, 68% more than workers without those skills. “We shouldn’t fearmonger, but we can’t pretend our training and worker support systems are ready, either. It’s time for innovative and practical solutions,” said Raimondo. “RAISE US gives state leaders a playbook that connects more Americans with the skills and careers needed in the years ahead,” said Holcomb. He emphasized that workforce development is an “all hands-on-deck moment”, not an issue divided along political lines. “I learned this work gets done at the state level, in partnership with employers—not by mandates from Washington,” said Holcomb. The press release states that RAISE US is partnering with leading global technology companies and labor groups, and is building a set of partnerships to support its research, policy, and employer-engagement work with numerous research and consulting groups. “We’ve assembled the country's leading companies, best economists, and philanthropy at a scale rarely seen—all to advance new ideas and incentives, pilot them with governors and business, and scale what works,” said Raimondo. "I want the workforce of Connecticut to look at the years ahead and see opportunity, not uncertainty,” said Lamont.  For Connecticut manufacturers, the initiative could help strengthen the pipeline of workers with AI and advanced technology skills as companies continue adopting automation and digital manufacturing tools.
CONNSTEP celebrated its 25th anniversary with a gala at Hartford's historic Bushnell in Hartford, CT
June 16, 2026
Your input will directly shape the programs, resources, and events we deliver—ensuring they reflect what matters most to you and your business.
25 Years of CONNSTEP: Celebrating the People and Partnerships Powering Connecticut Manufacturing
By Amanda Beaulieu June 4, 2026
On March 25, 2026, CONNSTEP celebrated its 25th anniversary with a memorable gala at Hartford's historic Bushnell Performing Arts Center.
WHI Global Expands Aerobond Composites Manufacturing Operations in Enfield
May 14, 2026
WHI Global, a leading vertically integrated manufacturer serving the aerospace and defense industry, announced the opening of its Aerobond Composites manufacturing facility in Enfield.
Worker using a polishing wheel on a vanity top.
By Amanda Beaulieu May 5, 2026
Manufacturers across Connecticut are navigating a rapidly evolving landscape. Your voice and your needs matter. Take The Manufacturer’s Voice Survey today.
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.