INITIAL SITUATION
- Lack of Transparency on the Shop Floor, missing alignment over all hierarchy levels.
- Poor level of order fulfillment, resulting in high cost for extra time and special freights.
- Poor utilization of machines and employee available knowledge
- Quality problems resulting in high cost for scrap and rework
PROJECT DESCRIPTION | APPROACH METHODS
- Lean assessment applying the standard tools for analysis:
- Value stream mapping and design
- Change over analysis including production planning review
- Shop floor evaluations and problem solving standards
- Financial analysis to support project selection
- Lean daily management system to visualize and systemize KPI´s and problem solving and escalation
- 5S, SMED and line balancing to boost capacity and flexibility in production
- Implementation of a continuous improvement system
PROJECT RESULTS
- Shop floor management implemented with a clear structure from top management to operator level. Escalation system and problem solving tools standardized and all employees trained
- Order fulfillment increased by more than 80%, reaching 96%. Cost of extra time and special freight reduced by 95%, while WIP was reduced by an average of 40%.
- OEE (plastic injection) increased from an initial 67% to a stable 84% in the first year.
- Top management and key mid-level management trained and coached in change management tools and approaches.
