AN Polymers is a plastic products manufacturing business that moulded industrial plastics to make domestic and commercial RO systems and equipment as well as an array of automobile plastic parts and electrical & telecommunication products. In addition to their own private label product, Essex RO, they also manufacture for Aquaguard and Kent. The facility houses 4 injection moulding machines of 150-450 Tonnes.
The client wished to get out of the production system issues so as to develop distributors across nation for their new product. Production capacity of the plant was 35,000 pcs per month whereas the client was currently producing only 22,000 pcs per month. The client wished to increase his production capacity in order to meet the demands for his new product. Also the workplace was not very well maintained and there was no concept of 5S in the organization
We did an initial assessment of the manufacturing setup to create the Value Stream Map and identify their bottleneck operations. We compared this with the national average to identify the ROI from each activity. Four 5S teams were formed and training was provided to the team on 5S benefits and implementation methodology. Each team consisted of a Sookshm’s Consultant and 3 client’s staff who showed great interest in the initial training. 5S was initiated with ‘Red tagging’ at each work area. Standard operating procedures were created for the marketing, material handling, production and dispatch teams to ensure sustainability of the process and help them train new staff in a more effective way. Time and motion study was done at the assembly unit. Based on the study a new assembly line was suggested which improved the output of the line by 25%
- The production capacity was increased to 28,500 pcs per month which helped them meet their demands for the new product.
- Reduced the lead time for the top 5 products by 15%.
- Space saved for around Rs. 1.20 lakhs. The time spent by the directors on the production issues was reduced from 2hrs per day to 0.5hrs per day