Converting/Packaging
Issue:
Two converting lines are struggling to keep pace with customer demand. Part outages have been identified as one of the major contributors to converter downtime.
Scope:
Develop a method to ensure parts availability through the use of lean tools and practices. Converter uptime should improve as a result of this effort.
Approach:
This line is a contract manufacturing line with variable demand based on customers needs. The takt for this line was set for 90% of the converting line capability. A team developed supermarkets that contained one shift’s worth of material. The team then identified replenishment areas at equipment and worker point of use to be filled from the supermarkets. By the end of the five (5) day event, supermarkets were established, areas marked out and employees trained on the new system.
Results:
Within two (2) weeks outages at the converter were a memory. Six (6) months after establishing the program, output on the converting lines had doubled. The warehouse was initially concerned that the supermarkets would require more space for materials but the predictable nature of the supermarkets has actually freed up warehouse space to be used as manufacturing space.