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Lean Implementation for Plastic Moulding Manufacturer

 

 

CLIENT CONTEXT & PROBLEM

 

The client is a leading manufacturer of plastic furniture, crates, drums and, pails. The manufacturer was experiencing poor operating results and struggling with frequently missing commitments in the market in spite of high finished goods inventory.

APPROACH & SOLUTION

 

Consoul team assessed existing inventory controls, product costing and processes to determine the level of accuracy and controls over the information and the quality of the output as a basis to make decisions. We reviewed the company’s product mix related to its costs to determine the profitability of different segments of the company based on product type.

Solution Highlights:

 

  1. Applied the Theory of Constraints (TOC) framework and lean manufacturing principles to identify the bottlenecks and streamline the operations on the shop floor

  2. Designed and developed a comprehensive MIS with operating metrics such as OEE, EPQ, Inventory turnover, and Cycle time

  3. Practical workshops for operators and coaching for front line managers for skill improvement (Bottom Up) and enabled the easy input of data

 

BUSINESS RESULTS

  • Empowered management with OEE scorecard by compounding the effects of availability, performance and quality losses on a day to day basis

  • MIS dashboard for managerial decision making with powerful drill down analysis on the basis of product, shift and plant

  • Established trends over weeks and months in order to support the long-term improvement cycle

  • Reduced the inventory levels by 14% or improved the profitability by 5% with SKU rationalization and removed unnecessary planning complexities

  • The large and varying manufacturing lead-times crashed to one-third of the original lead time within 6 months

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