Last fall, Mallard Creek Polymers (MCP) was named a winner of the 2025 KAIZEN Awards North America, in recognition of a continuous improvement initiative at our Charlotte manufacturing facility. Kaizen Institute has now released a full video case study documenting how the work was done and what it took to sustain the results.
The initiative focused on standardizing changeover processes and aligning operators, engineers, and leadership around a shared improvement framework.
The outcomes:
- 40% productivity improvement target, exceeded by 16%
- 15 changeover types reduced to 9 standardized processes
- One unified continuous improvement language across the entire facility
The video features firsthand perspectives from Plant Manager Paul Winkley, Continuous Improvement Manager Tim Dolin, and Project Engineer Nicholas Hartsell, covering how the team applied value stream mapping, SMED principles, and standard work to reduce variability and sustain the gains over time.
For our customers, this kind of operational discipline matters. More consistent processes mean more reliable output, more consistent quality, and a manufacturing partner who is continually raising the bar.
Watch the case study »
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