Improving the production of cardboard packaging

Context

  • Factory in Eastern Europe supplying local market with cardboard packaging

  • Tough competition with customers seeking lowest prices for these commodities

  • Growing market, but the factory is unable to keep pace

  • Very low utilization of productive capacity 

Approach

  • Brief diagnostic and rollout of performance improvement project focused on bottleneck machines

  • Training and coaching of management team

  • Training and deployment of Lean methods and tools, like 5S, SMED, spaghetti charts, FMEA...

  • Periodic time-boxed training sessions with coach and ongoing improvement driven by local management team

Results

  • Video analyses of changeovers using SMED

  • Standardisation of small tools and tightenings, reinvigoration of 5S

  • Definition of 3 generic typologies for changeovers and allocation of new standard times, definition of roles among the shopfloor team and work instruction update

  • Improving adjustments to achieve "right the first time"

  • Identification and reduction of minor stops causes

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About Marris Consulting

Marris Consulting is an industry consulting and training company specialized in the Theory of Constraints (ToC) and Critical Chain Project Management. We focus on improving the performance of manufacturing and process industries by using Constraints Management combined with Lean and Six Sigma. To boost project performance, we also use Critical Chain Project Management (CCPM), which we sometimes combine with Lean Engineering. Our 2-day performance audits, our performance consulting services and our project management, Lean & ToC training by our industry consultants offer a wide range of solutions to help our clients around the world reach the highest possible levels of performance.

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