Lean Transformation and Training Within Industry (TWI) Result in Higher Efficiency for Itek Energy

Company Profile

Itek Energy (is now Silfab Solar).

In August 2018, SilFab Solar - North America’s leading PV module manufacturer, today announced a direct investment into Itek Energy, LLC to initiate its United States operations and to meet growing demand for its high-performance, high-quality solar panels.

At the time of our engagement Itek Energy was a premier manufacturer of high-quality, assembled in America solar modules based in Bellingham, WA.

Solution

The objective of the training program was to create a culture of continuous improvement and lean practices, as well as enhancing supervisor and production skills to facilitate the growth Itek Energy is experiencing. The training focused on sustained growth and improvement practices, high quality and customer service. The workforce required skills training in the following areas:

• Actual solar panel manufacturing processes, (Training Within Industry [TWI]).
• Supervisory skill training to ensure existing and newly appointed supervisors have the needed skills and to aid in the growth of the company and successfully onboard new employees.
• Continuous Improvement, Quality Assurance and Lean Enterprise.

Results

Overal improvement of employee morale was realized as a result of the training along with the following:

• Significant reduction in the failure rates of finished products
• More efficiency in producing products
• More organized, efficient workplace
• Rework of nonconforming solar panels has dropped an astounding 80% due to the problem solving
• These improvements will be transferred over to the new expanded facility on the Bellingham waterfront that will allow Itek Energy to triple their production rates in the future over their current facility