Production Assessment and Lean Kaizen

$200M Contract Manufacturer

Background

  • Rapidly growing contract consumer packaged goods (CPG) company was struggling with overall equipment effectiveness (OEE) and could not supply the market demand
  • There dynamic was complicated as production was sourced through a contract manufacturer

Contributions

  • 3-day assessment which led to an actionable rapid results plan
  • 24×7 floor presence to coach and drive results
  • Daily and weekly downtime and overall equipment effectiveness (OEE) reporting
  • Implemented a visual management solution
  • Optimized resource effectiveness through the development of leadership standard work (LSW) and skills assessment
  • TPM program deployment and central claim management system (CMMS) selection and implementation
  • 9 full day Kaizens, covering 38 operations SOPs

Results

  • Improved OEE by 26 points in 12 weeks
  • Doubled unit output within 12 weeks
  • Improved transparency through redesigned metrics reporting, creating data driven improvement actions
  • Transitioned from a 6×24 3 shift schedule to a 24×7 2 shift schedule
  • Reduced downtime through CMMS implementation and a complete spares inventory plan