Corrugated/Converting
Issue:
This leading manufacturer of corrugated boxes is competing in an environment expecting lower run minimums, lower order quantities while providing faster turnaround times. Productivity was suffering due to long set-ups and inventory turns were slowing, and lead times extending as the organization was still trying to run orders the "old way".
Scope:
The scope of this project was to reduce set-up time by 50%, reduce the waste of travel by 50%, implement 1 quality improvement and 2 safety improvements.
Approach:
A set-up reduction kaizen team was formed and pre event work was completed (observation of change over and video taping). The team reviewed pre-work and identified internal versus external tasks as well as brainstormed other improvement ideas to reduce or eliminate wasteful steps. Improvement ideas were tested, verified and implemented.
Results:
