leading plastic packaging disposables manufacturing in UAE. Introduction of integrated Lean Six Sigma Kaizen as a Operational excellence Strategy and create a road map and implementation for 2 factories.
Customized training on Lean Six sigma at all the levels, involvement of operators in Daily work management, Focus on getting first time right. Rewards and recognition, More focus on 5 S , TPM and Kaizen systemization
Integrated lean Six sigma implementation at a food grade plastic disposable products mfg. co. at UAE
Client:
A leading plastic packaging disposables manufacturing in UAE.
Challenge
Introduction of integrated Lean Six Sigma Kaizen as a Operational excellence Strategy and create a road map and implementation for 2 factories.
Project:
Identify key themes and important improvement projects and mobilize resources and support for the whole initiative for long term.
Approach:
Lean Six sigma approach for problem solving which includes Assessment of process and activity, OEE of critical lines , gap assessment, yields, prioritization according to criticality, mistake proofing of the overall manufacturing process.
Project:
- Redesign of electrical mosquito repellant.
- Redesign of low smoke coil.
Approach:
DMADV approach for redesign.
Activities :
process mapping and capability analysis, introduction of DMAIC approach and Tollgate Reviews, processes, training and ongoing coaching.
Results and Financial Returns:
- Improved GE / OEE from average 60% to 70% for all the critical lines.
- COPQ reduction of $4 million per annum.
What Makes This a “Lean Six Sigma” Project?
- Improvement of OEE.
- Involvement of employees in Kaizen initiatives.
- Intensive use of process metrics and basic 7 QC tools methods.
The Lean Six sigma toolkit:
Vale Stream mapping, Process capability analysis and metrics, cause and effect analysis, Pareto analysis, OEE 9 step process for improvement, Kaizen, CFT approach, Balanced score card.
How did we engage people and drive change?
Customized training on Lean Six sigma at all the levels, involvement of operators in Daily work. management, Focus on getting first time right. Rewards and recognition, More focus on 5 S , TPM and Kaizen systemization.
Gazelles added value:
Extensive experience in Manufacturing Process Improvement initiatives by providing customized solutions for Cultural and technical challenges.
comments
The case study on the DFSS methodology was incredibly insightful. It demonstrated how systematic redesigns and innovations can lead to significant improvements in product reliability and market success. The detailed approach to integrating DFSS with existing processes was particularly useful for our own projects.
I found the case study on OEE Improvement and Defects Reduction through Lean Six Sigma to be highly relevant. The practical examples and quantitative results highlighted the effectiveness of Lean Six Sigma in driving operational efficiency and reducing waste. It's clear that implementing these strategies can have a substantial impact on manufacturing performance.
The case study focusing on waste reduction and setup time reduction provided valuable insights into how Lean Six Sigma can address specific challenges in manufacturing. The results, including the cost savings and efficiency gains, were impressive and demonstrate the potential benefits of these methodologies in our own operations
Reading about the redesign of the electrical mosquito repellant and low smoke coil was fascinating. The case studies provided a clear picture of how targeted redesigns can lead to both cost savings and improved product performance. The approach taken was methodical and practical, offering great lessons for our supply chain processes