A manufacturer of rotationally moulded plastic and Fire protection products supplying the automotive and traffic management industries. Employing over 30 staff, 20 of which are directly involved in the manufacturing process.

The brief

Identify areas for efficiency improvements as a key element of an overall strategic business review as a plan for future growth and increased profitability.

The following areas for improvement were immediately identified. Poor workplace organisation created delays and High levels of WIP and finished stock tied up cash and storage space. A lack of performance measurement (OEE) on the key items of equipment meant processes were under-utilised. A lack of Key Performance Indicators at both shop floor and business levels made it difficult to improve because there was no bench mark. Tackling the above challenges also gave the business the opportunity of creating a culture of team working and continuous improvement. The whole team was involved and focused on practical, action oriented improvement activity.

Activities Undertaken

Following the initial visit, the Practitioner worked with a small team of shop floor leaders and operators on some simple but highly effective improvement techniques. They were introduced to basic Lean principles and then took part in a three day workshop on 5S Workplace Organisation, which included transforming a pilot area of the factory floor.

Further work was done with the team to map manufacturing processes (Value Stream Mapping) and identify areas where ‘waste’ could be eliminated to reduce cost and increase productivity. Once these changes were implemented, the management and shop floor teams were introduced to the OEE to help them understand how they could make their machines work harder. All techniques were tailored to the requirements of the business and rolled out across the shop floor.

Results

Productivity improvements have so far realized a 15% improvement. This has allowed the business to manufacture many of its products on a 2-shift operation rather then 3-shifts.
OEE improvements have so far been in excess of 10%.
Stock Turns up by 25%, with an actual improvement in Customer Service levels.
Improved Space Utilisation on the factory has meant that the offices have now been relocated into the same building as the production operations. This will add year on year to the business profit through rent and rates savings. The business has now embarked on a new customer initiative which is already reaping benefits.

Copernicus – Guiding your business to operational success