Company: Innovio Films
Sector: Process Industries – Manufacturing and Packaging
Key Tools or Services; Implementation – Measurement, OEE , 7 wastes, problem solving
Results:
- Factory waste reduced by 23%.
- Short maintenance stop duration halved.
- Average colour change time reduced by 33%.
- Demonstrated a sustained increase in m/c running speeds of 5%.
Project Overview
Large potential financial benefits were identified through a PICME benchmarking activity for this client and so the business chose to embark on a programme of Picme facilitated improvement activities focussing on reducing material waste. Three shop floor based, cross functional teams were set up to reduce waste in three key manufacturing departments on the site.
Although top level waste figures were well understood by the business, a lack of detailed waste information at a shop floor level meant that significant opportunities for improvement were missed. Each team was facilitated by experienced Picme Engineers through a process of data analysis and detailed measurement to identify the specific issues contributing to poor yields.
Structured problem solving and operational trials were then used to develop new Standard Operating Procedures and machine settings that minimised waste in key areas. These were implemented by training the new procedures to each of the shifts in a 5 rotating shift system and developing simple visual management techniques.
The results were a reduction in factory wide material waste of 23%, from a total annual waste bill in excess of seven figures.