The recognition follows a multi-year transformation of Stonhard’s New Jersey operations. In 2019, the company launched a major capital project to consolidate two manufacturing sites into a single, modernized facility in Maple Shade. Completed in fall 2023, the project included the installation of a new tank farm, a comprehensive plant floor re-layout, and the relocation of thirteen major pieces of process equipment and associated packing lines.
While Stonhard began adopting MS-168 principles in 2018, the Maple Shade team accelerated its efforts in fiscal year 2024 with a renewed, plant-wide focus on engagement, accountability, and performance measurement. Clearly defined metrics were established across all production areas, supported by enhanced training and alignment initiatives for team members at every level.
The impact was transformational. By fully embracing MS-168 at all levels of the organization, the Maple Shade facility unlocked additional capacity, improved operational efficiency, and fostered a safer, more engaged work environment. Through multiple continuous improvement initiatives, including several Green Belt projects, the team reduced waste, increased flexibility, and improved responsiveness to customer demand.
As a result, the Maple Shade facility achieved:
- A 60% reduction in made-to-order lead times, from 10 weeks to as little as 4 weeks.
- A 50% increase in plant throughput, raising average monthly output from 1-1.5 million pounds.
These improvements significantly enhanced Stonhard’s ability to serve customers and support continued revenue growth. Operational gains also enabled a 22% reduction in overall inventory, lowering days of inventory on-hand by 14 days and contributing to a 248 basis point improvement in working capital company-wide.
Momentum continued into 2025 as Stonhard further expanded its MS-168 efforts. Enhancements included the addition of Tier 1 meetings within Quality Control and Maintenance, expanded visual factory displays across all packaging lines, and the launch of Tier 5 meetings to better connect plant performance with measurable financial outcomes.
Today, made-to-order lead times have been reduced to between three and four weeks, with an additional eight-day reduction in days of inventory on hand. The facility’s improved agility has enabled Stonhard to capture emergent sales opportunities, many with lead times of two weeks or less, all without disruption to shop floor operations.