| Client
:- |
Manufacturer
of Urostomy Products, supplied across Europe. |
| Situation
:- |
Part
of an International group, producing a range of medical products with
customers across Europe and suppliers around the world |
| Objective
:- |
Improve
productivity to meet increasing demand, reduce costs and release much
needed space. |
|
| Proposal
:- |
Select
and train an Improvement Team on a Lean Manufacturing techniques, then
work with Improvement Team to analyse production area, eliminate waste
and develop new layouts and methods. |
| Approach
:- |
Trained
Improvement Team on Lean Toolkit and worked with them to analyse current
situation over several weeks. Developed new concepts & layouts with
team and then trained team members to train others on Lean Manufacturing.
Team Members then trained all operators and support staff.
Improvement Team implemented new layout and methods and when target rates
were achieved, team handed cell over to newly Hosca trained Team Leaders. |
|
| Results
:- |
Performance
at start of study :- |
| |
- 15,500 bags per day
- 24 people on 2 shift working
- Work in progress = 200,000 bags
- Space taken = 1,000 mē
- Value adding ratio = 0.016%
- Throughput time = 92 hours.
- O.E.E. = 40%
|
| |
Improvements
Delivered :- |
| |
- 20,000 bags per day
- 15 people on 2 shift working.
- W.I.P. reduced to 20,000
- Space required = 300 mē
- Value Adding Ratio = 1.9%
- Throughput Time = 47 minutes
- O.E.E. = 65
|
|
| Further
:- |
Following
successful implementation of this cell, a company wide education and training
on Lean Manufacturing.
|
|
