About Freefoam.

Freefoam Plastics Ltd came to us because they wanted to reduce their operating costs and improve the quality of their product. We introduced them to the tools they needed to help get them there and worked with them to nurture the development of a culture of Continuous Improvement.

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Every staff member really started to understand quality, not just as a concept, but in terms of actual behaviours and actions.

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The Challenge.

The starting block for improvement was to secure the support of Senior Management we knew that change would flow from this. Working with the team at Freefoam we shared the purpose of the programme with all team members, then we embarked on a stabilisation programme with the company. This saw the company introduce Lean 6 Sigma and Visual Management the result being that a clear and safe work environment was established for all employees. Work could then be measured by way of PIT (Performance, Issues and Threats) Boards

A Collaborative Solution.

By introducing morning meetings (a max of 15 mins) at the PIT boards the company was in a position to identify problems and resolve or escalate the issue as necessary. Various issues surfaced, including challenges with set ups, changeovers, product defects and WIP. Green Belt training was also employed to help equip the teams with the skills they needed to resolve some of the key issues. By working closely with Freefoam, LBSPartners was able to guide the company towards achieving sustainable actions for the BETTER of the company and its employees.

Impact and Results.

  • Increase in Injection Moulding throughput and 98% yield
  • Reduction of 50% in change overtimes on the foiling machine
  • Improved packing time by 30%
  • Reduce stock holding by 60% due to shorter lead times


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