Benchmarks & Client Cases

Daily Management in Process Industry

The Challenge


High levels of waste and lack of material organisation
High levels of waste and lack of material organisation


Poor information sharing
Poor information sharing

Problem

• Lack of available operational indicators

• Poor team coordination and workplace organization

• Ineffective sharing of information during shift handover



Root Causes

• Weak culture of Continuous Improvement and lack of routines

• Teams not held accountable for performance results

• Lack of investment in team morale and motivational initiatives

• Limited involvement of team members in improvement projects



The Solution

Team meetings with visual management
Team meetings with visual management
Workplace organisation
Workplace organisation
Standard Work
Standard Work
Quarterly Auditing System
Quarterly Auditing System

• KPI System: to collect and process manufacturing indicators

• Daily Team Meetings: supported by team boards with KPIs, work plan, definition of priorities and improvement cycle

• Workplace organization contributing to improved productivity and reduction of errors

• Standard Work to improve process efficiency and reduce process variability

• Quarterly Auditing System to guarantee the sustainability of the solutions implemented and kick off new improvement projects

The Results

The new improvement routines of the teams generated annual savings of $49,000 per year.


OEE

OEE

Average equipment efficiency increased by 10%

Yield rate

Yield rate

Material consumption reduced by 9% as a result of improvements to yield rate.



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