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Company Profile

Kamaka Hawaii Inc., of Honolulu, manufactures high-quality ukuleles, parts, and accessories. Established in 1916, Kamaka Hawaii is a family-owned and operated business with fewer than 50 employees. The leading supplier of ukuleles to the Hawaii marketplace, the firm also sells its product in the continental United States and Japan. In recent years, however, Kamaka Hawaii's market has expanded faster than its capacity to meet demand.

Situation

With product demand outpacing its production capacity, Kamaka Hawaii was considering moving to a larger facility to allow for expansion. For help with this decision, the company turned to the Hawaii MEP, now known as HTDC-MEP, a NIST MEP network affiliate.

Solution

After attending Hawaii MEP's first Lean Manufacturing workshop, General Manager Fred Kamaka, Jr. realized his company did not need to move but could instead improve its process flow. With Hawaii MEP's help and his own engineering background, Fred acquired valuable lean manufacturing concepts, immediately implementing those critical to the company's success. Chris and Casey Kamaka also attended the lean workshop and have contributed to the firm's lean initiatives. By implementing lean manufacturing methodologies, Kamaka Hawaii was able to reduce work in progress (WIP) by 60 percent, thereby reducing space requirements and damage to the product from excess handling. Reduced WIP has had the added benefit of streamlining the production process and simplifying order entry, which has led to improved customer service and flexibility to manufacture specific products as they are ordered. Most important, Kamaka Hawaii was able to remain in the same facility, avoiding the expense of moving to a larger facility, while expanding production.

Results:

• Implemented lean manufacturing methodologies.
• Decreased work in process by 60 percent.
• Reduced space requirements and product damage.
• Streamlined production process.
• Simplified order entry.
• Improved customer service and flexibility in manufacturing specific products as ordered.
• Avoided expense of moving to larger facility, while expanding production.

Testimonial

"After attending the lean manufacturing workshop sponsored by the Hawaii Manufacturing Extension Partnership, we realized that our space requirements and work in process could be drastically reduced."

-- Fred Kamaka, Jr., General Manager, Kamaka Ukelele

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