Lean Application Case Study

Paper Mill

 12 week lean transformation wave initiated.

  At the end of the same:

 77 viable ideas collected by the team under lean

Identified savings of 4120 man hours

Identified cost savings of £71,646

Key learning points from the exercise included the need to keep a sharp focus on addressing issues through ‘top 10’ prioritisation, planning root cause/reliability meetings to take place adjacent to or even in the impact area of the identified issue to ensure the active involvement of all relevant people and enhanced supervisory involvement through facilitation, action planning, visual indications of progression and the lubrication of improvement recommendations ...

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The Identification and Elimination of Waste is not just about waste going into a bin, it also includes mechanical failures, reduced output, process interruptions, grade changes and reduced speed.

All forms of waste cost money, the less waste the greater the potential for profitability in real terms.

Industry finds itself in a situation where attention to detail and in depth performance monitoring really does give results. If we look at the best manufacturing plants and machines we find those with self managed shift teams are far more effective than those without i.e. the importance of the contribution of individual team members to the team and the need for teams to address issues as they happen ‘on shift’, cannot be emphasised enough.