Garrett Metal Detectors, the Garland, Texas, based manufacturer of security and hobby related metal detectors responded quickly and effectively to mounting orders for walk through and hand held detectors that spawned from the 2001 terrorist attacks. The Company’s ability to successfully meet the demands of their customers came, in part, through the training and project assistance they received from the Texas Manufacturing Assistance Center (TMAC).
Founded in 1964 by Charles L. Garrett, Garrett Metal Detectors has become a globally recognized name for hobby and security related metal detection products and technology. Over the past 40 years, Garrett has continually exceeded customer satisfaction by offering innovative products as well as pioneering technology in the metal detection industry. They have supplied equipment to every Summer Olympics since 1984. Garrett recently celebrated their 40th anniversary in business and acknowledged the value of TMAC as an important strategic partner.
In 2001, officials at Garrett Metal Detectors decided to pursue a Quality Management System which turned out to be the start of long term collaboration with TMAC.
As they were gathering information on ISO 9001, a supplier suggested the Company speak with TMAC representatives. Garrett, had recently hired a new production manager, who was principally interested in manufacturing support and redesign of their walk-through metal detector operations as well as increasing the Company’s competitive edge. Following a tour of Garrett’s manufacturing facilities; TMAC identified major improvement strategies for the Company’s production assembly.
TMAC eliminated several non-value added operations throughout Garrett’s assembly line that affected the Company’s production. Following Lean Manufacturing training, the Garrett/TMAC team improved product flow by determining how to balance assembly operations. Initially, an assembly employee walked over 150 yards to deliver materials from a stock table to an assembly station. That number was reduced after implementing a new line configuration.
The first day TMAC integrated its production methods into Garrett’s assembly line, the team produced more units than previously imagined. The cycle time to produce one unit was dramatically reduced from days to hours. In fact, the Company’s production output now meets the 300 percent demand for security units from government, corporate and private clients across the country. Bob Podhrasky, Sr. Vice President and Director of Research & Development for Garrett Metal Detectors noted, “The manufacturing concepts TMAC implemented throughout our Company have empowered us with the ability to increase production three to four times over. We were surprised to learn that you can implement lean concepts and still grow your workforce.”
By June 2002 Garrett and TMAC completed the ISO 9001 Quality Management System, which resulted in the Company’s successful registration to the ISO 9001 standard. In order to pass the ISO certification audit, Garrett’s management, manufacturing and office staff worked in concert to take their existing quality system to the next level. Garrett’s 40-year quality history was formulated into a clear and concise “Quality Policy” that each member of the Garrett team can explain as well as execute. Furthermore, as the demand for security equipment continues to escalate, Garrett’s ISO certification ensures that every detector sold by the Company’s authorized dealers around the world arrive in flawless condition.
Perhaps the most significant impact the Lean and Quality Management system has produced for Garrett is the ability to successfully compete for additional security related metal detector contracts. This was recently confirmed when the Transportation Security Administration (TSA) awarded Garrett with a contract to supply walk through metal detectors to over 100 U.S. airports (including the Dallas/Fort Worth International Airport) as well as serve as the supplier of hand held detectors for airports located throughout the world.
“The Quality Management System we implemented with TMAC has met, even exceeded every requirement mandated by the TSA ,” added Podhrasky. “As a result, Garrett has been able to pursue additional domestic and international customers. We were recently awarded contracts to supply equipment to Iraqi security forces and to Spain’s airports. I have no hesitation that the systems we currently have in place will continue to drive our sustained growth.”
During 2004 Garrett launched their ACE Series of rugged hobby detectors. They employed one of TMAC’s graduate students as a design engineer for start-up production. They wanted to implement lean elements during the design phase to address improved methods prior to ramping up for full production. The Ace Series has been so popular that TMAC is now assisting Garret with the manufacturing layout of a 45,000 square foot expansion necessary to accommodate the growing workforce which has doubled from 60 to 120 over the past nine years. TMAC was also instrumental in contributing to a major cost reduction in this line’s stem assembly.
Garrett was unaware the European Union and several U.S. states are soon to require electronics manufacturers to be in compliance with the WEE and RoHS standards for products containing lead and other hazardous materials. (WEE: Waste in Electrical and Electronic Equipment and RoHS: Restriction in certain Hazardous Substances). TMAC advised Garrett of the upcoming requirements and because Garrett has a significant international market, staff has now been dedicated to develop a Wee & RoHS compliance program. This should enable Garrett to make a determination on the components used in their manufacturing processes and also give them competitive advantage by complying early-on. Garrett management has indicated that exposure to this kind of information is invaluable as they continue to move forward in their global market.
“The manufacturing concepts TMAC implemented throughout our Company have empowered us with the ability to increase production three to four times over.”
Bob Podhrasky
Senior Vice President
Garrett Metal Detectors