Amarr – Employee Empowerment
Partnering for Progress: How KMS Helped Amarr Unlock $12.6M in Savings
THE MANUFACTURER
Founded in 1951 by Abe, Morris, and Herb Brenner, Amarr has grown into one of the world’s premier brands for sectional doors, serving both residential and commercial markets. Every Amarr product is proudly made in the USA, carrying forward a long-standing tradition of innovation, quality craftsmanship, and sustainability.
Today, Amarr operates more than 60 Door Centers across the United States, Canada, and Mexico. With a full range of options — from roll-up doors to aluminum full-view styles — Amarr designs doors that are not only durable and secure but also enhance the look and feel of homes and businesses.
Amarr doors are available through a trusted network of over 4,000 independent garage door dealers throughout North America, ensuring reliable installation, replacement, and service. Customers can also find Amarr products at leading retailers including Costco, Sam’s Club, and Window World, making them widely accessible to homeowners and businesses alike.
THE SITUATION
Amarr, a leading manufacturer, was looking for ways to:
- Strengthen efficiency
- Reduce waste
- Empower employees to take ownership of process improvements
While they had a committed workforce, they needed a structured approach to continuous improvement and a partner to help guide the way.
THE SOLUTION
Kansas Manufacturing Solutions (KMS) partnered with Amarr to implement a comprehensive Lean Six Sigma training initiative, tailored to employees at multiple levels:
- Introductory Training: One-day sessions across four dates for employees to learn Lean Six Sigma fundamentals.
- Green Belt Training: Three full-day sessions over three weeks, with hands-on projects and homework, preparing employees for certification.
- Black Belt Training: Three weeks of advanced instruction (one day per week), requiring project work, documentation, and a proctored exam for certification.
To achieve certification, Green and Black Belt participants completed Lean Six Sigma projects that directly applied to Amarr’s operations.
THE RESULTS
Amarr realized measurable impact across their operations:
- $10.8 million in cost savings through improved processes and efficiencies
- $1.8 million saved by avoiding unnecessary investments
- Staffing efficiencies equal to 40 positions (achieved through attrition, not layoffs)
- Improved morale, engagement, and retention through employee empowerment
In total, Amarr achieved $12.6 million in savings and created a culture of operational excellence.
THE CONCLUSION
"Kansas Manufacturing Solutions helped us with continuous improvement training, and it turned things around here. Their expertise helped our team sharpen their skills and think differently about our processes, boosting productivity across the board. We’re seeing less waste and more efficiency, and our folks are more motivated than ever. It’s been a huge boost for our growth."
— Mike Bernholtz, Plant Manager