Arizona MEP and Arizona Western Fixture and Display Inc., Build New Sustainable Growth Processes
Arizona Western Fixture and Display, Inc. is a Tucson-based manufacturer that designs and produces custom fixtures and displays for a wide range of customers. Founded in 1984 by Bernard Narcy in his garage, the company’s products can now be found at La-Z-Boy Inc. stores, LCG Everbrook Academies, UnitedHealthcare, OneAZ Credit Union, and Vantage West.
Arizona Western’s continued growth is driven by a disciplined manufacturing process and a dedicated team operating out of a 30,000-square-foot facility.
The Situation
Arizona Western’s goal is steady, sustainable growth. However, leadership was unsure whether the right processes were in place to support long-term success. In 2021, after connecting with Arizona MEP Senior Client Advisor Michael Jimmerson, the company applied for Arizona MEP’s Emergency Assistance Program (EAP), which supported manufacturers impacted by the COVID-19 pandemic.
As part of the engagement, Arizona MEP worked with Arizona Western’s leadership team to assess business needs and develop a plan focused on:
- Learning and implementing Lean manufacturing principles
- Improving inventory management and updating safety stock levels
- Developing a new website to attract employees and clients
- Conducting a safety program audit and training
Lean Manufacturing Improves Team Structure and Efficiency
Arizona MEP began by focusing on reorganizing production teams. In May 2021, Arizona MEP conducted a Lean 101 workshop with leadership and followed up with two additional sessions to deepen understanding.
One key concept introduced was tiered management teams. With support from Arizona MEP Continuous Improvement Expert Kyle Randels, Arizona Western transitioned from a single large production team reporting to one plant manager into smaller teams of three to four employees, each led by a team leader. Teams were assigned to production, packaging, and shipping areas.
The new structure delivered several benefits:
- Improved employee retention by creating advancement opportunities
- Empowered teams to standardize production processes using Lean principles
- Reduced communication bottlenecks by distributing leadership responsibilities
Root Cause Analysis Strengthens Quality and Consistency
With the new structure in place, Arizona Western implemented a formal root cause analysis process. “Arizona MEP helped us implement a ‘stop the line’ process where employees can halt production to address issues immediately,” said Pamela Narcy, Controller at Arizona Western.
This approach allowed defects to be identified earlier in the process rather than at final inspection. Standardized workflows within each production cell helped teams identify root causes more quickly and resolve issues efficiently.
Inventory Improvements Strengthen Supply Chain Relationships
In June 2021, Arizona Western began experiencing supply chain disruptions related to the pandemic. Arizona MEP’s inventory management expert collaborated with the company to assess practices and establish new safety stock levels for high-volume, critical items.
“Hinges, staples, nails, nailers, and staple guns are supplies we need across every job,” said Narcy. “When we run out, production stops.” Increasing inventory levels for these essentials improved supplier relationships and reduced delivery frequency and costs during a period of rising fuel prices.
New Website Supports Hiring and Business Development
Using EAP funds, Arizona Western worked with Arizona MEP’s digital marketing expert to launch a new website. The updated site showcases completed projects installed at client locations and serves as a platform to promote new employment opportunities.
Continuing the Partnership
Although Arizona MEP’s EAP program has ended, Arizona Western continues its partnership with Arizona MEP. The company remains committed to Lean principles, and one employee has since earned Six Sigma Black Belt certification.
Future projects include human resources training for new team leaders, conflict resolution support, communication skills development, and a new safety program with Arizona MEP’s safety expert. Company leadership also continues to attend Arizona MEP workshops focused on critical business topics for manufacturers.
“When we first took the Lean 101 class, we didn’t know the direction it would take us,” said Narcy. “That was exciting because it took us in a whole new direction. Michael and Kyle at Arizona MEP really helped us understand how to start successfully. We’re still partnering with MEP because it’s been such a valuable resource to our company.”
In June 2021, Arizona Western started to feel the disruptions to the supply chain due to the pandemic. Arizona MEP's inventory management expert collaborated with the company to assess its inventory management practices. As a result, the company implemented new safety stock levels on high-volume items essential to production. "Hinges, staples, nails, nailers, and staple guns are supplies we need across any job," said Narcy. "When we run out of stock of these supplies, production stops." Arizona Western increased the amount of inventory it carried for hardware items. Doing so improved its relationship with suppliers, which could then reduce the number of delivery trips to the facility and save delivery costs amidst rising gas prices.
New Website Attracts New Employees and Showcases Projects
Using the funds from the EAP, Arizona Western was also able to update its website using the Arizona MEP's digital marketing expert. The company now has a modern platform to showcase finished projects installed at its clients' locations. The website also helps the company advertise new employment opportunities.
Continuing the Partnership
Even though Arizona MEP's EAP program has ended, Arizona Western has continued its relationship with Arizona MEP. The company continues implementing Lean principles, and one employee is now a certified Six Sigma Black Belt. Future projects with Arizona MEP include human resources training for new production team leaders on how to resolve conflicts and communicate effectively. Arizona MEP's safety expert will be working with the company on a new safety program and training. Narcy also regularly attends Arizona MEP workshops, which offer education on business topics critical to manufacturers.
"When we first took the Lean 101 class, we didn't know the direction it would take us," said Narcy. "And that was exciting because it took us in a whole new direction. Michael and Kyle at AZ MEP really helped with that decision and how to start successfully. We are still partnering with MEP because it's been such a valuable resource to our company."