Latest Success Story: Reducing by 3 the waste in a production section with higher value-added products. Undoubtedly, this type of project and achievement (€150,000-€200,000/year in reduced direct costs) is among the most complex because it requires integrating up to 7 improvement levers. Quality is the ultimate result of these ingenious production systems.

Last Success Story Divide by 3 the Scrap of a production plant with the most value added products. Undoubtedly this type of project and achievements (150-200K€/year of direct costs) are the most complicated because they require coupling a variety of levers for improvement. Quality being the ultimate result of these ingenious production systems.

Results achieved

Defined Production System

Step 1: Creation of Smart Reporting Tool and Management Visual Zone

Step 2: Process Management / “Virtual Manager”

Implementation of a “Virtual Manager”

Reminders and alerts about pending processes

More than 20 processes under control: Quality, Safety, 5S, MA, Checklists

SMED Process Continuous Improvement Module

Continuous Process Improvement Module MA

Step 3: Self-Maintenance & Continuous Improvement
Removing the Iceberg of Ignorance

Management of Self-Maintenance by the Operators

Classification of Incidents by Level of Criticality and Impact

Communication between repair shifts

Feedback and Improvement of MA Processes

Continuous Improvement Module with Operator Ideas

Incident Repetition and Response Time (SLA) Reporting

Step 4: Implementation of Excellence in Terms of Management 7S (5+2)

Step 5: Technical improvements for improved quality at the source and a reduction of micro-stops

Upstream Quality Optimization through Machine Optimization and Process Control

Step 6: Organizational Change

Design and Implementation of a More Efficient Organization:

• Specialization
• Reduction of displacements
• Process Standardization

Reduction of variability thanks to the specification of Team leaders

Summary of the Improvement Levers Implemented

Results achieved