Company: Jotun
Sector: Process Industries
Key Tools or; Services: Value Stream Mapping, Workplace Organisation, Output Improvement, Downtime Reduction, Lean Factory, Warehouse
Results:
- 7 figure increase in annual sales turnover
- 30% improvement in output through key assets
- 8% improvement in OTIF
- 29% improvement in stock turns
Project Overview
Following a Value Stream Mapping activity, this business embarked on a PICME change programme consisting of a series of facilitated improvement activities. A number of these activities were focussed on driving improvement in the manufacturing areas. After the completion of a successful activity to increase capacity in the filling area, a new team was set-up to target changeover time in order to improve flexibility in the department.
A shop floor based, cross functional team was assembled to apply the principles of Single Minute Exchange of Dies (SMED) to the filling line changeover process. Through a series of trials which were videoed and reviewed, improvements to the process were suggested by the team to reduce operator movement and make more effective use of the equipment available. The best practice method was then captured in a Standard Operating Procedure and trained to the other operators in the department.
Once the new changeover method had been fully implemented, a 50% reduction in the time required to change over a filling line was achieved.