Background:
A print company was looking to improve their operations using Lean and Green techniques.
Situation:
During a routine inspection, excessive materials were found in skips, particularly from changeover and splicing reels. A deeper investigation using A3 problem-solving methods uncovered several root causes:
- Lack of Maintenance: Equipment was not adequately maintained.
- Broken Parts: Critical components were malfunctioning.
- No Standard Work Procedures: Processes lacked clear guidelines.
- Outdated Service Contracts: Necessary services were no longer active or relevant.
Task:
To resolve the issues discovered in the A3 problem solving
Actions:
To address these issues, the team deployed classic Lean tools:
1. Total Productive Maintenance (TPM): Ensured machines were well-maintained and operational.
2. Job Instruction (JI): Developed standardized work instructions for consistency.
3. Service Contracts: Reinstated and updated contracts to cover machine servicing needs.
Results:
The improvements led to significant gains:
- 50% Reduction in Lost Time: Faster and smoother operations.
- 70% Reduction in Lost Materials: Drastic decrease in waste.
- £4,000 Savings in the First Month: Achieved with a single print machine.
- £200,000 Annual Savings: Expanded by rolling out the solution across three other print machines.
Key Lessons Learned:
.
- Effective Communication: Clear mission and leadership communication ensured alignment and focus.
- Lean Tools Work: Practical application of Lean methods can resolve even complex issues.
- Behavioural Change: Success relied on changing daily habits through systems and Leader Standard Work (LSW).
- Low-Cost Solutions: Significant improvements were achieved without large investments or “magic wand” projects.