Order planning and management

• Lack of order status control
• High level of administrative work
• Manual planning management / lack of synchronization

Efficiency Control

• Lack of efficiency reports
• Absence of lean methods Quality
• Lack of changeover time control

Maintenance

• Corrective-oriented
• Outsourced Management
• Absence of guidelines in the plant

NCIs & Reprocessing

• NCI Lack of Control
• Lack of systematic analysis and resolution

Centralization of Technical Knowledge

• People-centered knowledge
• Few defined/written/digitalized procedures
• Need for a rebalancing of technical knowledge between Operators and Supervisors

Summary of applied improvement levers

Summary of Production System Created

Summary of Production System Created

Organizational chart reorganization

Creating “Job Descriptions” for key positions

THEORETICAL TRAINING

Progress in the discipline and culture of perfection and continuous improvement

Summary of Production System Created

CONTROL & KPIS: LEAN REPORTING

A tool for focusing on efficiency and profitability results

Creation of a Reporting Satellite connected to the ERP allowing:

1. Control of gross and net speeds on a daily, weekly, and annual basis, per machine and operator
2. Monitoring of repair times at the daily, weekly, and annual levels by machine and operator
3. Efficiency and profitability of budgets visible by HR, machine, client, week, month, etc.

Implementations January-February: Management KPIs Module

Profitability ranking by machine and by customer

Cross-order profitability report with names and comments on machinist incidents to encourage analysis and continuous improvement

PRODUCTION & SALES EFFICIENCY CONTROL

Control from micro to macro: Machinists, Machines, Orders

Efficiency monitoring across all timeframes from the monthly level down to the shift-based machinist level

Control sales efficiency and margin of each job

Order Efficiency Control by Machine, Customer, Month, Week, Orders

CONTROL & KPIS: LEAN REPORTING

A4 Efficiency Report

Summary of Production System Created

Before / After: Starting Point

5S: Order to maximize machine efficiency 801

5S: Order to maximize machine efficiency 803

Standardization: Order and location of tools and consumables

Before/After: Results

Disposal of obsolete

1stS in films: Removal of Obsolete References for:

1. Reduce search and machine replenishment times
2. Improve waste consumption and reduce film cost/m2

Warehouse adaptation and visual organization

Standardization of storage by type and size

Implementation of separators to increase storage capacity

Mixed references and formats + presence of obsolete references

1. Visual order by reference and format
2. Obsolete items removed
3. Increased warehouse capacity
4. T search reduction
5. SATISFACTION OF THE ENTIRE STAFF

Visual Management in Warehouse

Films / Samples / Photolithographs and soon engravings

Consumables Finder Software

Stock Control Tool and Quick Search with Keywords

Summary of Production System Created

Implementation of the First Processes

Implementations January-February: Cleaning procedures

Implementation of order and cleanliness guidelines at the end of each shift

SMED checklist for preparing and supplying orders to production by internal logistics with quality check

Process Map Definition

Summary of Production System Created

Lean Planning

Implementation of Pull flow throughout the pre-sales and pre-production chain + 4 Concorde-type “hyper-connectivity” terminals for real-time control of the status of all orders

Implementations January-February: Digital planning workflow

Interconnection of the departments: Technical Operations, Orders, Purchasing, Logistics and Production. Notifications of previous incidents and technical management modules for Purchasing and Logistics.

Implementations January-February: Engravings Warehouse + Logistics Warehouse 1

Summary of Production System Created

Quality Zone: Making Quality Visible

Implementation of Quality Tools

NCE control, machine control checklists and sample release

Implementations January-February: Non-Quality Management Module

Quality management tools:

• Full registration
• Control KPIs
• Communication & NC Resolution