Multi Site Manufacturing company

About this Organisation.

Not all of our clients wish to be identified. Some wish to remain anonymous – sometimes to retain an ‘edge’ over a competitor. That is understandable and never an issue for us to accommodate. If and when discretion is called for, we work with the client to keep the project under wraps, providing advice and guidance on how best to do so.

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The Challenge

This manufacturing company has a main production line which feeds a finishing line. Both departments operate 24/7. The Finishing line was not achieving the production volumes to satisfy customer demand and was in frequent backlog.

A Collaborative Solution.

Working with Production and with Process Engineering, we first set up a PIT process to monitor and visualise the results in the Finishing line. OEE2 was selected as the key performance indicator on the line. It was clear that an opportunity existed to improve the Line OEE2 results. An A3/DMAIC problem solving project was started with the team. Results were measured and the baseline OEE2 was measured before the improvement program began. We worked with the operators and with Manufacturing engineering to identify the main losses. The main loss was associated with speed loss on the machine to facilitate the operators to feed the line and to do post pack operations on the product. We rebalanced the work for the operators and standardised the speed settings on the machine. WIP planning was also optimised.

Due to Covid19 restrictions, most of this work was completed remotely with the client. Digital tools combined with good client engagement on the line ensured the success of this project.

Impact and Results.

Production Productivity was improved by 23% in the first 4 months and production volumes increased to eliminate customer supply backlogs. While volumes reduced on this product line post-improvement (capacity was diverted to a new product), once volumes recover again, overall margin is calculated to increase by over €400k per annum.

Capability was built within the company to enable the team to do further problem solving, and a new target was agreed to improve OEE2 in the department by a further 10% in the following 4 months.

We are now planning to do a similar project with a sister plant.

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