The Northwood-based manufacturer of plastisol-coated steel products had strong sales but recognized that future growth was constrained by limited space and workforce availability. Their plans involved investing millions in land acquisition, a substantial building expansion, and integrating robotics. To ensure success, they sought guidance from CIRAS.
“Turning to CIRAS was a natural choice,” said ADA Enterprises president and CEO Tom Stensrud. “We’ve had a long and productive partnership with CIRAS, and we value their expertise.”
Stensrud reached out to Derek Thompson, a CIRAS strategic advisor who has worked with ADA for decades. Thompson collaborated with CIRAS project manager Kirk Haaland to develop a comprehensive plan, including facility design, equipment selection, and robotics integration.
“ADA had around 80 percent of the plan in place,” said Haaland. “We helped refine the plan and provided clarity to confirm they were on the right path for such a high-stakes project.”
CIRAS broke the project into three phases. Haaland worked closely with ADA to optimize plant flow and layout, providing 2D AutoCAD designs to illustrate the proposed expansion and its functionality.
The $5 million expansion is expected to generate $9 million of economic impact for the company.
“Partnering with CIRAS for guidance and expertise has become second nature for us,” said Stensrud. He noted that while ADA is not large enough to employ a full-time engineer, they frequently need engineering and manufacturing advice. “CIRAS is the perfect solution,” he added.
When seeking strategic input, Stensrud appreciates that CIRAS’ primary mission is to help Iowa companies succeed. “Their focus is on our success— not on selling us something,” he explained.
This client-centric approach is a core value of CIRAS. “We’re here to help companies make the best decisions, not to push specific products,” Haaland emphasized.
ADA specializes in a niche market: outdoor picnic tables with unique plastisol coatings. Recently, CIRAS connected ADA with an Iowa State professor experienced with plastisol in another industry, sparking innovative ideas.
“It’s been transformative,” Stensrud said. “Their insights have helped us think creatively about our processes.”
ADA also benefits from CIRAS programs like the Iowa Lean Consortium (ILC), which provides education and collaborative learning to enhance efficiency and profitability.
As part of a previous expansion, CIRAS alerted ADA about surpassing the 50-employee threshold, triggering compliance with the Family and Medical Leave Act. CIRAS guided ADA through the process, ensuring a smooth transition.
CIRAS also supported ADA’s adoption of robotics, assisting with grant applications, process design, equipment selection, and implementation coaching.
“One memorable project involved redesigning our plastic coating process,” Stensrud shared. “Iowa State tested our proposed changes, helping us assess durability and make informed decisions.”
Reflecting on the partnership, Stensrud said, “CIRAS has been instrumental in reducing risks and enabling our growth.”
For more information, contact Derek Thompson at thompson@iastate.edu or 515-419-2163.