Efficient Plant Jan./Feb. 2021 - 26

feature | solution focus

PM Accelerates
Bedding Mfg
Efficiency
Keeping up with demand
has required a highly
efficient manufacturing
operation and a culture of
continuous improvement.

Uptime tracking provides increased operational availability and
production rates for comfort-tech company.
FOUNDERS TONY AND Terry Pearce, brothers and both engineers, knew their company, Purple, Lehi, UT, (purple.com), needed
its own manufacturing facility. Purple is a comfort-technology company that designs and manufactures products such as mattresses,
pillows, and seat cushions. The brothers knew that they didn't want
their plant to go through all the cycles that many other companies
typically experience, including implementing homegrown processes.
They wanted to leverage best practices while developing production
facilities that are as innovative as their products.
Purple was growing fast and needed their plant floor to match
that speed. Downtime is an ever-present danger, and they needed an
operations partner that could keep their production lines moving.
Leading2Lean, Sparks, NV, (L2L.com), was brought in to provide
their Lean Execution System (LES), a platform that could scale with
Purple's growth, while taking little time and effort to update. Purple
began with L2L Maintenance. Not long after seeing the positive
maintenance results, the company deployed L2L's LES Production
Module.
The first phase of the Purple L2L project focused on providing
real-time data to improve maintenance and reliability processes

26

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EP2101fsolfocus.indd 26

in the company's Grantsville, UT, plant. L2L's web-based software
allowed the maintenance team to quickly launch the planning and
scheduling of preventive-maintenance functions. The LES Maintenance suite provided real-time performance data that was used to
spot and respond to reactive issues.
LES Maintenance usage results included:
 development of an asset-numbering protocol for all the equipment
in the facility
 labeling each machine or asset within the plant
 incorporating all facility assets into the system, including items such
as urinals and fire extinguishers
 sourcing, purchasing, and assigning laptops for 14 members of the
Purple maintenance staff so they could easily use the L2L Maintenance
module
 providing six- to seven-day training for the maintenance and production staff on use of L2L software (training was timed during shifts
and the plant was not shut down during training)
 capturing data immediately upon completion of an activity
 creating and executing preventive-maintenance tasks, starting with
critical equipment

JAN/FEB 2021

1/26/21 12:12 PM


http://www.purple.com http://www.L2L.com http://www.EFFICIENTPLANTMAG.COM

Efficient Plant Jan./Feb. 2021

Table of Contents for the Digital Edition of Efficient Plant Jan./Feb. 2021

Efficient Plant Jan./Feb. 2021 - Cover1
Efficient Plant Jan./Feb. 2021 - Cover2
Efficient Plant Jan./Feb. 2021 - 1
Efficient Plant Jan./Feb. 2021 - 2
Efficient Plant Jan./Feb. 2021 - 3
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Efficient Plant Jan./Feb. 2021 - Cover3
Efficient Plant Jan./Feb. 2021 - Cover4
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