Waste Reduction and Setup Time Reduction through Lean Six Sigma

A large multinational FMCG group having a multilocation plants across India. To reduce the chronic problems related with Rawmaterial and packaing material wastages and reduce changeover times.

Expertise in Lean six sigma engagement across all the strata of management and rigorous review mechanism added value to the overall implementation process

Waste reduction and setup time reduction through lean Six sigma

Client:

A large multinational FMCG group having a multilocation plants across India

Challenge:

To reduce the chronic problems related with Rawmaterial and packaing material wastages and reduce changeover times

Project:

To ireduce the wastages of RM/PM by 50% and reduce changeover time by 30%.

Approach:

Use blended approach of Lean Six sigma / DMAIC and statistical alongwith TPM tools.

Activities:

process mapping and capability analysis, introduction of DMAIC approach and , Basic 7 QC tools and Statistical process control.

Results and financial returns:

:: Overall RM / PM waste by 45%.
:: Reduction in changeover time by 30%.
:: Approx cost reduction of Rs. 1.5.crore per annum.

What makes this a “Lean Six Sigma” project?

:: Focus on identification and reducing the waste.customers and internal defects.
:: Intensive use of process metrics and quantitative methods.
:: Focus on changeover time reduction crucial from flexibility point of view of the facility

The Lean Six sigma toolkit:

Process mapping techniques, Process capability analysis and metrics, Basic seven QC tools , Anova and hypothesis testing and regression analysis, Statistical Process Control (SPC).

How did we engage people and drive change?

CFT working , Customised workshop , rigorous tollgate reviews by engaging the top management, involving vendors wherever required, Involved all the concerned on the shopfloor in solution generation and SPC implementation through Kaizen / CFT working /.

Gazelles added value:

Expertise in Lean six sigma engagement across all the strata of management and rigorous review mechanism added value to the overall implementation process.

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