Food Packaging Manufacturer Needed to Ramp Up Production
About the opportunity
• Phase 1 – Equipment troubleshooting: We started by identifying and tackling issues with the equipment causing downtime or defects. We continued by collaborating with the team to develop corrections or modifications to the equipment to avoid defective parts and interruptions.
• Phase 2 – Problem-solving : We installed basic problem-solving devices such as production control boards and visual management boards. This enabled us to focus on the immediate issues but also to understand the mid-term trends of performance so that the team could start addressing those proactively.
•Phase 3 – Process documentation: We proceeded to develop documentation such as standard work procedures and Failure Modes & Effects Analysis to help the organization continue to execute and have the references for troubleshooting future issues.
• Improved yield rate by 70% (from 10-20% to > 90%) for number one obstacle equipment.
• Improve throughput in production cycles by 300%.
•Improved overall yield by 60%.
We have developed and used a proven approach to ensure manufacturers achieve and sustain significant performance improvement. Our consultants have over 15 years of experience working with manufacturers and developing their capabilities.