Client: Jotun

Sector: Process Industry - Manufacturing and Packaging

Key tools or services

Lean Implementation, OEE Improvement, Value Stream Mapping, Workplace Organisation, Output Improvement, Downtime Reduction, Lean Factory, Warehouse, Configured filling line components & workstation

Requirement

Following a Value Stream Mapping activity, Jotun embarked on a picme^®change programme consisting of a series of facilitated improvement activities. A number of these activities were focused on driving improvement in the manufacturing areas where a lack of capacity meant that volumes of key products were being transferred to other sites in the group.

Response

One shop floor-based, cross-functional team was set up to look at filling line output. Initially the team carried out a detailed analysis of filling line performance using Overall Equipment Effectiveness and applied 5C workplace organisation, implementing new ways of laying out materials and finished goods around the line. Using these improvements to change the way raw materials were delivered to the line and the way in which finished goods were removed, immediately brought about improvements in machine running time.

Next, the team carried out a more detailed analysis of machine and operator activity during the filling process. This led the team to implement a new line layout to improve operator access, to investigate and implement changes in the way certain key packaging materials were sourced and to change standard operating procedures to capture best practice. Finally a visual management system was implemented to monitor and improve filling line performance. The result was an increase in filling line throughput in excess of 30%.

Result

• 7 figure increase in annual sales turnover
• 30% improvement in output through key assets
• 8% improvement in OTIF
• 29% improvement in stock turns

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