How Justice Design Group Achieved Operational Excellence with CMTC’s Lean Manufacturing Expertise
In today’s competitive manufacturing landscape, businesses must continuously adapt to meet growing demands while maintaining quality and efficiency. For Justice Design Group (JDG), a Los Angeles-based decorative lighting fixture manufacturer, scaling operations presented unique challenges that required expert guidance. Enter California Manufacturing Technology Consulting® (CMTC), which provided tailored Lean Manufacturing training and consulting services to help JDG strengthen its operations, expand capacity, and prepare for future growth.
A Legacy of Innovation in Lighting Design
Founded in 1985, Justice Design Group has built a reputation for designing and producing high-quality, clean-lined lighting products for residential, hospitality, and commercial settings. Known for its modular line of lighting fixtures, JDG artfully incorporates specialty materials into distinctive shapes and designs, setting itself apart in the industry. However, as the company grew, so did the complexity of its operations. Challenges such as maintaining consistent quality, optimizing processes, managing increased production demands, and training a growing workforce began to surface. To address these issues and successfully scale their business, JDG leadership turned to CMTC for support.
Addressing Challenges Through Customized Training
CMTC conducted a comprehensive analysis of Justice Design Group’s operations and identified key areas for improvement. The consulting team then implemented targeted strategies to streamline workflows, enhance productivity, and improve overall efficiency. Key initiatives included:
- Lean Manufacturing Training: CMTC introduced JDG factory personnel to Lean principles and 5S workplace organization techniques. These methodologies helped simplify complex processes, reduce waste, and ensure consistent product quality. By adopting Lean practices, JDG was able to address operational bottlenecks and improve its ability to meet rising customer demand.
- Warehouse Reorganization: One of the most impactful changes involved reorganizing JDG’s warehouse to maximize space utilization and improve On-Time Shipping (OTS) rates. With CMTC’s guidance, JDG reduced its 95,000-square-foot facility by renting out unused portions, creating significant cost savings. Additionally, an ABC analysis was performed to strategically position best-selling products closer to order pickers and the shipping department, further enhancing logistics efficiency.
- Workforce Development: Recognizing the importance of employee engagement, CMTC focused on developing JDG staff through customized training programs. Employees gained valuable skills in workflow optimization, inventory management, and leadership. This not only boosted individual performance but also fostered a culture of continuous improvement within the organization.
Measurable Results and Long-Term Benefits
The collaboration between CMTC and Justice Design Group yielded impressive results. According to JDG estimates, the partnership led to:
- A $600,000 increase in sales, driven by improved operational efficiencies and enhanced capacity to handle higher production volumes.
- $150,000 in cost savings, achieved through better resource allocation, reduced waste, and optimized warehouse space.
- The creation of three new jobs and retention of two existing positions, underscoring the positive impact on employment and workforce stability.
- A total investment of $225,000, allocated across new products/processes ($25,000), equipment upgrades ($25,000), IT enhancements ($75,000), and workforce development/training ($100,000).
Beyond financial metrics, the initiative improved employee morale and performance, fostering a more cohesive and motivated workforce. The trust established between JDG employees and CMTC advisors laid the foundation for ongoing collaboration, including preparations for ISO 9001 Certification and future Continuous Improvement projects.
A Partnership Built on Trust and Shared Goals
Brandon Levin, President of Justice Design Group, praised CMTC’s role in driving JDG’s success: “CMTC has been and will continue to be a long-term partner of Justice Design Group. We’ve worked with CMTC on numerous engagements over many years. As we have additional needs to further improve our operations and provide additional training in the future, we’ll certainly partner with CMTC.”
This enduring partnership highlights the value of external expertise in navigating the complexities of modern manufacturing. By leveraging CMTC’s specialized knowledge, JDG was able to overcome operational hurdles and position itself for sustainable growth.
Why This Collaboration Matters
The success story of Justice Design Group serves as a testament to the transformative power of Lean Manufacturing and strategic consulting. In an era where manufacturers face increasing pressure to innovate and optimize, partnerships like the one between JDG and CMTC demonstrate how targeted interventions can drive tangible results. From boosting revenue and reducing costs to enhancing employee satisfaction and preparing for certifications, the benefits extend far beyond immediate gains.
For companies looking to scale their operations or address inefficiencies, this case study offers valuable insights. It underscores the importance of investing in workforce development, embracing proven methodologies like Lean and 5S, and partnering with trusted advisors who understand the nuances of manufacturing.
A Bright Future for Justice Design Group
With CMTC’s support, Justice Design Group is now better equipped to meet current market demands and anticipate future trends. The company’s commitment to innovation, quality, and sustainability ensures that it remains a leader in the decorative lighting industry. Meanwhile, the groundwork laid by CMTC paves the way for JDG to pursue ISO 9001 Certification and other milestones that will solidify its competitive edge.
As Justice Design Group continues to grow, its collaboration with CMTC stands as a shining example of how strategic partnerships can illuminate the path to success—proving that even the brightest achievements often begin with a single step toward improvement.
About California Manufacturing Technology Consulting® (CMTC)
Established in 1992, California Manufacturing Technology Consulting® (CMTC) is a private non-profit organization that provides technical assistance, workforce development, and consulting services to small and medium-sized manufacturers throughout the state of California. CMTC operates under a number of cooperative agreements with the Federal and State government, the largest of which is with the Hollings Manufacturing Extension Partnership (MEP) of the National Institute of Standards and Technology (NIST) under the Department of Commerce for the State of California.
