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Reducing waste and space with 5S
Posted By L1ghth0useAdm1n On March 2, 2011 @ 3:52 pm In case studies,lean,private sector,reduce costs,training | Comments Disabled
McLelland Cheese Packaging package cheese produced at other Lactalis locations, cutting large blocks into the required sizes, packaging them into airtight plastic and then packing the blocks into boxes for transportation to supermarkets.
Business Situation:
There was a very crowded, unsuitable and untidy working environment in the low care Case Packing. There was far too much material around, poor visual management, inability to see issues in production – or indeed see the staff at times.
Excess material, e.g. boxes and shrink wrap, was transported multiple times and damaged, and the transportation on forklift trucks in a crowded environment was leading to machine damage.
Part rolls of shrink wrap were being piled up and wasted, with a current 7% wastage on materials.
Business Solution:
The challenge was to implement 5S (Workplace Organisation) in the case packing area and to use this as a pilot for rolling out 5S across the rest of the organisation. It was recognised that organising the Case Packing area would have the biggest impact on the factory, and would be the biggest incentive to believe implementation was possible elsewhere.
A multi-functional team undertook five days of training in 5S, fully implementing 5S in the whole of the pilot area; and setting up a Production Board to show 5S audit results and Production data.
Results:
Scottish Manufacturing Advisory Service
Lighthouse Consultants is contracted to provide Lean Manufacturing support to clients on behalf of SMAS.
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