As Insta-Pro International continued to grow its supplier base, the company partnered with CIRAS to implement a structured quality management system that improved internal processes, strengthened supplier communication, and saved an estimated $190,000.
Company Overview
Location: Polk County, lowa
Founded: 1969
Employees: 45
Primary Products: Grain and bean processing equipment, extruders, oil processors, coolers, and parts.
Situation
Insta-Pro International, a Polk County, lowa-based manufacturer of specialized equipment that helps customers produce chemical-free livestock feed ingredients, vegetable oils, and soy food products, began noticing quality issues as they added new suppliers. The problems were traced back to purchased parts that didn’t meet specifications. While frontline manufacturing workers were doing their best to fix defective parts as they arose, this reactive approach wasn’t solving the root cause, and problems continued to reach customers.
Recognizing the need for a structured quality program, Insta-Pro hired a dedicated quality team member and wanted to bring in some expertise to kick-start their efforts. To develop an effective quality management system and strengthen supplier relationships, Insta-Pro turned to CIRAS’s Operational Excellence team for guidance.
Solution
CIRAS conducted an in-depth current state mapping session with stakeholders from across Insta-Pro’s operations, including purchasing, receiving, manufacturing, and quality personnel. This collaborative approach revealed gaps in incoming inspection processes and in-line quality checks throughout the manufacturing process. CIRAS helped Insta-Pro develop and implement a comprehensive quality management system:
Incoming Quality Control: CIRAS guided Insta-Pro in establishing quality parameters and inspection procedures for purchased parts at receiving, including protocols for collecting and verifying supplier specification sheets.
Supplier Documentation: Many suppliers lacked complete documentation for their parts. CIRAS helped Insta-Pro work with suppliers to document all specifications, creating a foundation for consistent quality and enabling alternative sourcing if needed.
Engineering Change Management: CIRAS implemented a formal change control process to ensure that when design modifications occurred, both internal teams and suppliers received updated specifications.
Quality Tracking System: The team from Insta-Pro created a tracking program that documented each issue, its origin, root cause, and corrective actions. This work was supported and reviewed by the CIRAS team and enabled Insta-Pro to identify patterns, provide supplier feedback, and prevent recurring problems.
The current state mapping session proved particularly valuable by revealing that manufacturing workers had been silently fixing defective parts rather than reporting them. The new quality system created clear communication channels and accountability throughout the supply chain.
Results
Following CIRAS’s guidance, Insta-Pro International established a dedicated quality team and implemented comprehensive quality procedures to verify parts upon receipt and confirm supplier drawings. As a result, Insta-Pro was able to save an estimated $190,000 due to fewer returns, reduced waste from rework and scrap materials, and improved operational efficiency.
“The team from CIRAS provided the support we needed to create our Quality Management System. Our team knew we needed to create structure, and the process that CIRAS guided us through was the catalyst,” said Jonathan Kingsbury, CEO at Insta-Pro International.
The new quality management system has strengthened Insta-Pro’s supplier relationships through clearer communication and documentation while positioning the company for sustainable growth.
Contact Emily Betz to learn more.