With help from training grants facilitated by RochesterWorks!, ORMEC Systems Corp. is steadily gaining ground in its quest to earn ISO 9001:2000 certification. For more than 22 years, the Rochester-based company has manufactured control systems for a wide range of general purpose factory automation applications. In recent years, ORMEC Systems has had to compete with an increasing number of foreign companies with significantly lower labor and manufacturing expenses. In order to compete effectively in this global market place, ORMEC Systems has been restructuring itself in a number of creative ways.

Dr. Edward Krasnicki, President and CEO of ORMEC Systems, explains that "by completing the training (funded by the grants), we will have the skill sets we need

Employee John Mosley works within the "Cable and Subassembly" cell. The area was restructured last year as a result of the lean manufacturing training. The recent ISO 9001 training took their manufacturing process to a new level of consistently high quality.

Starting from a Solid Foundation
Some of the groundwork to become more efficient was already in place. In 2003, the company had implemented company-wide lean manufacturing techniques. With help from RochesterWorks! Downtown Career Center Director Connie Felder, ORMEC had applied for and received a BUSINYS #32-I grant to roll out training that same year. "RochesterWorks! was very helpful in guiding us through the application process," says Human Resources and Facilities Manager Jim Stocker. "We used the #32-I grant to train employees on lean manufacturing principles as well as for software development skills and successful selling techniques."

With the lean manufacturing training completed, the company was increasing its productivity and decreasing costs when it became aware of a more global need: ISO 9001 certification. "In early 2004, we had a potential customer who was impressed with our lean manufacturing and technology, which represented a significant amount of business," says Stocker. "Because we were not ISO 9001 certified, however, we did not make it onto their approved vendor list." This event emphasized the fact that the key to opening doors in multinational businesses lay with standardizing processes and quality. Because ORMEC Systems is solidly on its journey toward ISO 9001 certification, business discussions with this customer have resumed.

Delivering Consistent Quality, Value and Performance
A sign on the manufacturing floor at ORMEC reads: "Be everywhere.Do everything.And never fail to astonish the customer." Complementary to ORMEC's mission statement, this philosophy underscores the company's commitment to exceeding their customers' value and performance expectations. By achieving ISO 9001 certification, ORMEC would join the ranks of companies worldwide that are recognized for attaining certain process, management and quality standards.

"As we work toward ISO 9001 certification, it's important that we make all our employees aware of our expectations and that they understand our new processes," says Stocker. He turned to RochesterWorks! once again for help with training funds. Business Services Manager Claudia Gately talked with Stocker about a New York State grant available to small and mid-sized manufacturers to strengthen and support the manufacturing sector and walked him through applying for the NY SMART #17-K grant. Because processing the #17-K grant can take 2-3 months, Gately recommended that the company also apply for a local customized training grant. Using Workforce Investment Act funds administered through RochesterWorks!, customized training grants are available in a much shorter time period. ORMEC received approval for the grant within days.

"The customized training grant allowed us to get a jump start," says Stocker. "We were able to train 25% of our employees on the elements of ISO 9001, and sent a test engineer who is the lead auditor for our ISO 9001 program to a software training seminar. He then developed a program for tracking non-conforming material that we are using today."

Because the training was interactive, employees can apply what they learned to the shop floor and make modifications that further enhance the company's manufacturing and quality processes. While the company waits for approval of further training funds through the #17-K grant, it is well positioned to continue its path toward ISO 9001 certification.

"Many of our employees now have the skill set to do the tasks necessary for achieving and maintaining ISO 9001 certification," says Krasnicki. "The training has given us very valuable results - consistency, efficiency, documentation, and continuous improvement."

He concludes, "We are positioning ourselves to be very competitive on a global basis. The assistance we receive from RochesterWorks! is helpful in allowing us to seek that objective so we can keep jobs in the area and grow the company and the community."

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