Challenge
A private equity-owned industrial manufacturer of metal and plastic cans, containers, and intermediate bulk containers was facing significant production issues.
The company needed to optimize asset performance across the plant network to meet customer demand.
Approach
- Implemented agendas, action logs, and accountability in daily plant management meetings
- Added standard lean daily management to highlight wins & drive corrective actions
- Installed visual floor controls to gain detailed operational data and indicate a ‘good’ vs ‘bad’ performance to staff
- Increased yield and throughput deploying total productive maintenance
- Created production wheel to drive longer runs and reduce changeovers
Results
Achieved 38% daily production increase vs plan
Increased On Time In Full (OTIF) shipments by 30%
Reduced changeover time by 40% to 50% with SMED
Demonstrated ability to run shifts with less than 5% downtime