Gaming machine maker IGT hits the jackpot by betting on a flexible new manufacturing strategy, eliminating cost and inventory.

International Game Technology PLC (IGT) is a global leader in the gaming industry, specializing in providing innovative and responsible gaming experiences across regulated segments. The company offers a comprehensive portfolio of products and services, including gaming machines, lottery systems, sports betting, and digital gaming solutions. With operations spanning major cities like London, Providence, Rome, Las Vegas, San Francisco, and Reno, IGT serves millions of players worldwide. Headquartered in London, UK, IGT is renowned for its commitment to delivering cutting-edge technology and engaging gaming experiences.

The Challenge

IGT faced significant operational hurdles as it scaled its business to meet growing customer demands. The company operated out of 17 separate facilities in the Reno area, which created inefficiencies in production and logistics. Increasing sales coupled with smaller order quantities and rising customization requests from clients added further strain to its manufacturing processes. Additionally, customers in the gaming industry often changed orders late in the production cycle, requiring IGT to adapt quickly without sacrificing efficiency or cost-effectiveness. Senior management recognized that continuing to operate as a fragmented job shop was unsustainable and sought a solution to consolidate operations, improve responsiveness, and reduce lead times.

The Solution

To address these challenges, IGT partnered with FloStor Engineering to implement a transformative manufacturing strategy centered on consolidation and automation. FloStor helped IGT consolidate its 17 facilities into a single 260,000-square-foot manufacturing and warehouse facility in Reno. This move streamlined operations and provided an opportunity to re-engineer production processes for greater efficiency. FloStor introduced powered conveyor systems to replace outdated non-powered conveyors, enabling progressive assembly lines that improved workflow and reduced manual handling.

Flexible Assembly Lines

FloStor designed flexible assembly lines capable of building any style of slot machine with minimal changeover time. The system included powered roller conveyors connecting eight assembly lines with 12 ergonomic workstations each. Common parts were delivered just-in-time using a Kanban system, while custom components were staged in vertical carousels with barcoded kits for accuracy. Cabinets queued in accumulation zones before being released one at a time to ensure uninterrupted flow through the assembly process.

Enhanced Workflow Efficiency

The new workflow implemented by FloStor Engineering transformed IGT’s manufacturing operations, emphasizing automation and ergonomics to streamline processes and improve productivity. These advancements reduced manual handling, optimized production flow, and enhanced operator comfort. Below are additional insights into the improvements:

• Optimized Production Flow: Powered conveyor systems ensured seamless movement of products through the assembly lines, minimizing delays and bottlenecks. Photoeye sensors automated the release of cabinets, maintaining consistent spacing and uninterrupted flow.
• Ergonomic Workstations: Adjustable lift tables allowed operators to work comfortably by customizing cabinet heights to their needs, reducing physical strain and improving efficiency. Proper workstation design minimized unnecessary movements and supported both seated and standing postures.
• Integrated Systems: The use of Kanban signaling for just-in-time delivery and barcoded kits ensured accuracy in component assembly, reducing errors and enhancing overall workflow precision.
• Continuous Monitoring: Real-time tracking tools provided visibility into production progress, enabling quick identification of bottlenecks and immediate corrective actions.

Continuous Improvement Initiatives

IGT’s commitment to continuous improvement has positioned it as a leader in operational excellence. The company embraced strategies such as real-time inventory tracking, supplier collaboration, and future integration of cabinet manufacturing onsite to further enhance efficiency. Additional initiatives include:

• Real-Time Inventory Management: IGT worked with suppliers to implement barcoding for incoming shipments, laying the groundwork for a warehouse management system that would provide real-time data on inventory levels. This system reduced paperwork, improved forecasting, and ensured timely replenishment of materials.
• Lean Manufacturing Practices: The integration of lean methodologies like Six Sigma and Kaizen helped identify inefficiencies and optimize resource usage across the production pipeline. These practices contributed to reducing waste while maintaining high-quality standards.
• Future Integration Plans: Bringing cabinet manufacturing onsite is expected to reduce internal lead times significantly while improving coordination between production stages.

Focus on Human Potential

IGT recognizes that its workforce is a critical asset in achieving operational success. By fostering employee engagement and leveraging high-performance teams, the company has created a collaborative environment that drives productivity and innovation. Additional initiatives include:

• Team Building Strategies: IGT invested in coaching programs to empower employees, improve collaboration, and enhance overall team performance. High-performing teams ensured consistent achievement of production targets while maintaining safety standards.
• Human-Centric Manufacturing: Inspired by Industry 5.0 principles, IGT prioritized human-centric approaches that amplify worker skills through synergistic collaboration with technology. This philosophy fosters creativity, adaptability, and resilience within the workforce.
• Employee Engagement Programs: Open communication channels, technology investments, and recognition programs boosted morale and alignment with organizational values, resulting in higher retention rates and job satisfaction.

Competitive Advantage in Gaming Industry

Through its partnership with FloStor Engineering, IGT has strengthened its competitive edge by delivering highly customized products efficiently while maintaining flexibility to meet evolving customer demands. Key factors contributing to this advantage include:

• Operational Excellence: Streamlined processes enabled faster production times without compromising quality or customization capabilities.
• Technological Innovation: Investments in automation systems reduced costs while improving accuracy and responsiveness to customer needs.
• Workforce Empowerment: A focus on tapping into human potential ensured a motivated workforce aligned with IGT’s strategic goals.