Electrical Power Distribution Manufacturer Overcomes Challenges to Deliver a Herculean Effort for the Customer

Logo of LEX, a company that delivers power, in blue, with the tagline

"This project involved quantities of product that we order of magnitude higher than what we normally deal with. The delivery timeline seemed unachievable. We have had a number of successful projects with Connstep over the years so we reached out to them. Connstep was able to recommend and implement a continuous flow process that cut our labor time dramatically and made the timeline achievable. The process also yielded higher quality. They used their expertise and experience along with dedication to the project. They guided us and were present every step of the way. There is no way we could have done this project on time without them."

—Bob Luther, CEO, LEX Products


LEX Products is a Shelton, Connecticut manufacturer of electrical power distribution equipment. Markets served by LEX products include entertainment, such as convention centers, the motion picture industry, and theatrical environments; government and military applications; portable and permanent power distribution systems for industrial markets and special events.


An Industry pioneer who introduced rubber enclosures for power distribution boxes, LEX is a rigorous builder committed to delivering the highest quality products and services in compliance with customers’ requirements to maximize their satisfaction. All products are built to ISO 9001 and AS9100C quality standards to meet the strictest safety codes.

  • Challenge

    A significant economic opportunity presented itself in mid-2019 for LEX Products to help meet the power demands for an overseas customer. This was a very large order for LEX with a very tight, firm deadline of less than six months with heavy penalties for late delivery.


    Given its long history with CONNSTEP as a partner in their Lean manufacturing journey, LEX reached out for help to meet the substantial demand for equipment to be built, tested, and shipped in time to meet the customer’s deadline.


    There were many challenges to overcome: components had not yet been purchased, suppliers had not been confirmed, production layout had not been defined, and UL approval had not been granted. Not to mention the need to hire and train close to 90 workers to meet production timetables.

  • Solution

    CONNSTEP immediately went to work after a few meetings with LEX management crafting a plan outlining where we could assist, offer guidance, and engage our consultants. A cohesive collaboration would be required to fulfill the customer order on the prescribed timeline.


    A technical subject matter expert from CONNSTEP worked side by side with LEX personnel for several weeks to:

    • tackle incoming materials schedules

    • determine capacity

    • calculate takt times

    • schedule UL qualification

    • integrate testing with production plan


    While there were a few problems with incoming materials as well as some assembly leaks, they were promptly addressed and corrected. Lean processes which had lapsed a bit at the company were reintroduced and resurrected to help accelerate forward progress on the project order and reestablish a Lean culture at LEX Products.

  • Result

    Despite the tight timeframe and complex logistics, all equipment items were shipped and delivered on time to meet the power requirements of the customer. CONNSTEP’s capacity analysis, cell design and detailed layout for LEX’s manufacturing area of their facility contributed to the project’s success.


    This collaborative effort maximized output while minimizing throughout time, labor, materials and product flow to ensure on-time delivery of the contracted product. Just another example of CONNSTEP’s dedication to helping Connecticut manufacturers be globally competitive and to treat businesses not just as customers but to leverage opportunities for meaningful collaboration.

Blue circle with upward trending white arrow, orange border.

Project Impact

$2,000,000 Equipment Investments

$30,000 Workforce Skills Investments

25 Retained Jobs

50 New 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.
April 28, 2026
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.
Penn Globe's Marcia LaFemina receives the 2026 Workforce Champion award from Governor Ned Lamont
April 24, 2026
Penn Globe's Marcia LaFemina receives the 2026 Workforce Champion award from Governor Ned Lamont
Photo of CONNSTEP President and CEO Beatriz Gutierrez with a congratulatory message.
By Amanda Beaulieu March 23, 2026
CONNSTEP is proud to share that President and CEO Beatriz N. Gutierrez has been named one of the Hartford Business Journal’s 2026 Women in Business honorees.
CONNSTEP Awarded $350,000 Federal Grant to Support Connecticut Manufacturers in Energy & Technology
By Amanda Beaulieu March 13, 2026
“We were pleased to get this grant,” said Congressman Larson. “It comes because of the mission, and it comes because of CONNSTEP’s initiative.”
CONNSTEP team photo
By Jaime Santos March 11, 2026
Explore success stories, register for trainings and events, connect with our team of trusted advisor, and access industry insights—all in just a few clicks.