Comprehensive intervention focusing on improving production and packing cell design, distribution centre systems improvements including a visual kanban system and an internal milk-run system, various process kaizen/LIFT events, scrap reduction, process yield improvements, material and energy cost savings.
- Project timeline: 35 weeks
- Project cost: $386,453
- Project annualized savings: $4,000,000
- Return on Investment: 10.4
Previous Layout and Material Flow
Current Layout
Improvements
- Improved material flow (also increased safety)
- Direct line-side staging of raw materials
- Forklift operate milkrunsin zones, one less driver needed
- Lines dedicated to families
- Offloading can be staffed by one operator
- Andon and material call installed
- Improved standardized work and line balance on a product family basis with major efficiency gains
- Daily management system put in place