A case study on vehicle lighting manufacturer, SoundOff Signal
Founded in 1992, SoundOff Signal is a manufacturer that produces specialty lighting, sirens and control systems for emergency and commercial vehicles. They are the second largest provider (domestically) in the law enforcement lighting market with a reputation for high-quality and durable products, enabled by their patented mpower® silicone lighting technology.
Facing Challenges
Despite strong growth and a leading market position, SoundOff Signal recognized several challenges in keeping pace with customer demand and staying competitive.
- Constrained production capacity in their manual assembly lines
- Difficulty recruiting and retaining employees for assembly work
- Increasing complexity in manufacturing their unique lighting products
Introducing Smart Manufacturing Solutions to the Floor
To address these strategic challenges, SoundOff Signal invested in developing two automated production lines, replacing three previous manual assembly stations. These automated lines incorporate innovations in riveting, adhesive curing, inspection and more to improve manufacturing performance.
Specifically, SoundOff Signal’s new process delivers:
- 30% faster production rates through precision automation
- Advanced sensors and analytics to continuously improve quality
- Ergonomic relief from repetitive manual labor
- Flexible systems that can adapt to produce new lighting designs
Impact on Competitiveness and Company Culture
Early results after deploying automated lines show an uplift in SoundOff Signal’s competitiveness and company culture:
- Production capacity increased from 60 units per hour to 100+ units
- Employees are cross-trained and redeployed to high-value, machine-operating roles
- Morale and engagement are high thanks to upskilling opportunities and the company’s ESOP model
“Employees are excited to expand the scope of their work duties and be part of the new production process,” remarked John Stelmach, manufacturing engineering manager. “When we first implemented, one employee came up to me and said ‘we’re going to produce a record number of units today!’ The shift to a new production process has been a motivator for employees.”
By strategically embracing smart technologies, SoundOff Signal unlocked the manufacturing performance and employee productivity needed to sustain strong growth and customer satisfaction for years to come.
The Business Solutions team at Lakeshore Advantage can help you get started, too. Reach out to Amanda Murray to get connected with the right resources for a smart investment in the future of your business.