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Improve Scheduling-103
The Situation:
A company that manufactures paper bags in the flexible packaging industry was losing margin and profitability in a highly competitive market. The Highland Group was asked to assist them in improving their operating margin using lean manufacturing techniques particularly in the area of production change over.
The Driver Goal:
- Improve productivity by 20% while reducing scrap by 10%
Actions Taken:
- Improved overall equipment performance using 5S and SMED techniques
- Implemented 5S System of organization and standardization across the plant
- Developed and implemented System for Management Reporting (top to bottom) and conducted Supervisory/Managerial Training Workshops on using system
- Developed and implemented a preventative maintenance program that included the machine operators
- Upgraded the Quality Assurance program
- Developed and implemented operator training programs for machine operation and machine set up and trained client trainers to train operators
The Results:
- Increased machine utilization by 35%
- Increased income 30% over budget.
- Improved throughput of operations by 43%
- Improved overall plant throughput by 67%
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