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US Playing Cards  About US Playing CardsTo remain the market-share leader in their industry, U.S. Playing Card needed to lead the way in product delivery and quality. This required a culture change of increased communication and accountability.
U.S. Playing Card is the world leader in the production and distribution of playing cards. For over 125 years Business NeedsUSPC had hit a homerun with the Iraqi Most Wanted decks. This quick growth challenged their systems, processes, and people. At the same time, Asian casinos had multiplied and the domestic casino market was growing into new locations at a fast pace.
USPC began seeing a need to protect and further improve service levels and lead times to both domestic and international customers. They decided to commit all resources toward this service level improvement focus. New challenges quickly surfaced. The long time owner of USPC’s exclusive distributor of casino playing cards in the Asian market visited the USPC Norwood facility to address all employees with the opportunity to secure new business by reducing defects. Just as they seized the Iraqi opportunity, USPC knew they had to move quickly to take full advantage of the circumstances. Immediate ChallengesJason joined USPC in June 2002 and mandated a greater level of delivery performance in all areas of the business. Jason wanted greater cooperation and accountability between departments and throughout the entire system. He wanted everyone to look at the business with a new set of eyes and bring fresh ideas. He needed a catalyst to allow his team to move quickly and grow with new opportunities. Jason knew that focus would lead to accelerated change and take them to the next level.
Increased delivery performance and reduced defects were needed to keep the gap wide between USPC and low-price competitors. A new planning system was critical to allow for better communication and proactive preparation for casino contract orders. USPC also needed to gain the confidence of the Asian market to allow them to continue to grow their presence in this market. Definity Partners PlanDefinity Partners began working in the shop with the printing experts to discover the symptoms of late deliveries. Solutions were implemented to make the right cards, at the right time, in the right amount by working hands-on with planning, customer service, information systems, and production departments.
A Master Production Scheduling system was implemented to capture and make informed decisions on contract business. Communication of demand was simplified and automated to dramatically affect lead time. Capacity planning tools were put into place to better equip the management to utilize the valuable printing press time, reduce inventory and consistently meet deliveries. Production processes were improved by eliminating waste to speed orders through the process. ResultsDespite changing circumstances, the USPC team stayed focused and committed to achieve the service level goal while also meeting the defect reduction goal. With daily communication, of actions taken and next steps, every department became more open to, and effective in, making rapid change together. This has opened new cost reduction opportunities on which USPC can now focus. The Figures
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