Engineering Industry
About Industry
Established in the year 1999, XYZ Laminates are one of the leading manufacturers and suppliers of a quality range of Flexible Packaging. They are engaged in the manufacturing of quality range of flexible packaging like laminated rolls and pouches, BOPP Pouches, display pouches, zipper & slider pouches and stationery accessories made from BOPP, laminated films and PP (Polypropylene). The company is having infrastructure around in 10000 Sq. Ft. and More than 100 Workers.
Basic Challenges of Company
- Labour Productivity is low
- Too Much Rejection is there
- Document Management is poor
- No Monitoring System of Energy Consumption
- Machine Downtime is high
- Inventory is Higher
- Space Constraints are there
- Unorganized Working Method
- No Worker Participation in improvement
Project Implemented: LEAN Manufacturing Practices
- To implement 5S practices & Visual Control to organize Workshop area
- Printing Cylinder storage Management
- To Implement Kaizen Improvement
- To Reduce machine downtime – (SMED& machine maintenance practise)
- To Reduce rejection
- Space management through the 5s Implementation and improving layout
- To improve delivery time by improving though put
- To suggest scope of improvement in energy efficiency by Energy audit
Implementation method
- Analysis of Present Situation
- Data Collection & Analysis
- Identification of Projects
- Presentation & Approval
- Phase wise Training & Execution
- Phase wise Reporting of Outcome
- Overview
Tools
- 5S
- 7 QC Tools
- Kobetsu Kaizen
- Pareto Analysis
- Visual Control
- Jishu Hozen
- Poka Yoke
- Problem Solving Tools
Quantitative Benefit
- 3900 kg Scrap Removed.
- 800 Sq. Fit Area Saved.
- Total 43.63 % of Improvement in Store Productivity.
- Machine Breakdown reduced by 35%
- Improved Work Efficiency by 69.30 %.
- Rejection has been reduced from 6.5 % to 0.07 %.
- 4 % Reduction in Production Cycle time
- 5 % reduced Energy Consumption “
Qualitative Benefits
- Wastage removed
- Non-moving item removes
- Smooth working & time saving due to quick retrieval
- Results in place easy to manage
- Company image improves
- Improvement in safety conditions in workplace
- Increased Worker Participation in Improvement
- Awareness about Lean Tools Created
- Improved Employee morale
Duration: 1 year
Monetary Benefits: 41,64,644 Rs. /Year
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