Productive processes improvement in three plants of the group

Need

Implement a Continuous Improvement system involving all the levels, stable and oriented to strategic results

Solution for the three plants

System based on Lean Manufacturing philosophy and oriented to Kaizen actions

Work in Kaizen cycles:

• Strategic deployment: director plan for the Continuous Improvement 
• Analysis Workshops
• Kaizen blitz

Systematic-method contribution and tools for improvement

Solutions brought by plant

Plant 1:

• Blitz for productivity improvement and painting lines cost reduction (manual and automated)

Plant 2:

• Blitz for visual management:
  • Design a Kanban system of replacement of critical pieces
  • Design a monitoring panel for incident control
  • 5S´s in tools

Plant 3:

• Workshop for defective reduction: poka-yokes patterns, suitable tools, pieces protection, locations maintenance, ...

Principal achievements

Plant 1:

• Increase of 20% the productive capacity by knowledge of the locations (balance to use the time outs in manual painting and in changing the chain parameters in automated painting)
• Consumption reduction of 20%
• Changing colour length reduction of 50%

Plant 2:

• Defective reduction
• Reduction of the stops caused by lack of material

Plant 3:

• Cost / piece reduction of 3,5% (by reducing the defective)