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Appleton: leading the way via lean manufacturing; The dust has settled after some key acquisitions, and Appleton is going to market as one unified films company and changing paradigms by using lean manufacturing to reduce lead times and drive inventory out of the system.

Publication: Flexible Packaging
Publication Date: 01-OCT-07
Format: Online
Delivery: Immediate Online Access
Full Article Title: Appleton: leading the way via lean manufacturing; The dust has settled after some key acquisitions, and Appleton is going to market as one unified films company and changing paradigms by using lean manufacturing to reduce lead times and drive inventory out of the system.(Appleton Papers Inc.)(Cover story)(Company overview)

Article Excerpt
Combining separate companies after acquisitions can be a difficult task, even for those organizations with well-defined cultures and corporate identities. The goal, of course, is to integrate the processes of the two operations into a seamless, cohesive organization. Such was the charge for Appleton as it integrated two related but separate films businesses under its corporate umbrella to present a unified films group to the marketplace.

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Based in Appleton, Wisc., Appleton is one of the largest entirely employee-owned companies in the United States. In 2001 the employees used their 401k money to invest and buy-out Appleton from the parent company. The buyout helped intensify a culture of ownership and pride within Appleton into a strong competitive advantage. Appleton's employees are engaged and interested in its success, a fact that helped facilitate the integration of the company's two films businesses.

Appleton's performance packaging division developed from the acquisition of three businesses. The first two were acquired in 2003 which included a flexible packaging converter in Merrill, Wisc. (C & H Packaging), and a multi-layer film producer in Rhinelander, Wisc. (American Plastics). New England Extrusion, a manufacturer of monolayer and co-extruded polyethylene film stock, was acquired in 2005.

INTEGRATED FILMS

Until recently, all three operated individually, just as they had before the acquisitions, but under Appleton's ownership. Now, the divison's executive management team, headed by Kathy Bolhous, vice president and general manager of Appleton's performance packaging division, has made a significant move to present a unified message and 'face' to the marketplace.

"We have been focused on integrating our film companies over the past year," says Bolhous....

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