Situation
Felker Brothers Corporation, a century-old industrial manufacturer, faced a common challenge in mature industries—how to innovate in a field where technology evolves slowly. By 2017, the company recognized it was stuck in a rut, with new ideas rarely progressing beyond management discussions. Seeking a structured path forward, Felker Brothers partnered with the University of Wisconsin-Stout Manufacturing Outreach Center (MOC) to transform its innovation process.
Solution
With the MOC’s guidance, Felker Brothers established a formalized system for evaluating and implementing new ideas. Central to this transformation was the creation of a Product and Process Development Committee. This group, composed of high-potential employees, reviews submitted ideas, conducts research, and evaluates return on investment before passing proposals to a Risk Management Committee. This committee then assigns tasks and oversees execution.
Results
- 46 concept cards submitted and reviewed by the Risk Management Committee
- 12 were denied
- 34 advanced to various stages
- Since adopting the new system, Felker Brothers has successfully completed approximately 20 projects, including process improvements, equipment upgrades, and personnel changes.
- The structured approach has significantly enhanced innovation outcomes across the organization.
- Employee engagement and leadership development have both seen measurable improvements.
- Regular project updates keep team members informed, motivated, and empowered.
- The system has fostered a culture of continuous improvement and collaboration.
One notable success was the approval and implementation of a seaming machine, which significantly reduced costs associated with importing materials and tariffs. The initiative exemplifies how a clear innovation pathway can lead to impactful operational improvements. Through their collaboration with the MOC, Felker Brothers has found a sustainable rhythm for innovation—one that honors its legacy while preparing it for the future.
Testimonial
“As an active member of PDC [Product and Process Development Committee] I enjoy the in-depth learning about our machines and processes, and what new machines could make that process look like. Through PDC I have become better at taking information and turning it into presentations with key data points to drive a desire for change, and in so have gained accountability and trust in delivering valuable decision making information. I personally have a long ways to go before retirement and want to see Felker succeed through my retirement. The only way for that to happen is through consistent innovation and I firmly believe it starts in PDC.” – Jesse Rabehl, Project Manager, Felker Brothers Corporation