This company installed the machine as
part of major capitol purchase two years ago. Despite there being
reliability issues with the operation of the machine, concern
was raised over it's ability to provided sufficient bars for downstream
Once the team had been trained in the
tools of lean, they process mapped what was currently happening
and then brainstormed ideas as to what they needed to make the
line work correctly.
They came up with thirty plus key improvements ranging from changes
of job roles through to the siting of CCTV and duplication of
control switches onto the main control panel.
The team took great pride in being able
to make a difference, supported by the business.
They achieved both tangible and intangible benefits, one of which
was increased sense of team working.
Back to case studies
Eradication of waste from and optimising
1. Potential freeing up of £1m cash
2 80% reduction in turn-time
Amazing how simple the tools were to use
and apply, the challenge is changing the culture of "we've
always done it this way" and out-moded production methodology.
Paul Warwick - Production Engineering