Case Study: Wiping Away Operational Challenges: A Journey Towards Enhanced Efficiency
Challenge:
Our client, a prominent player in the tissue manufacturing industry, was grappling with operational inefficiencies. Despite a significant investment in a state-of-the-art converting machine, they were unable to achieve optimal run rates. The Overall Equipment Efficiency (OEE) was a mere 32%, far below the industry standard.
Approach:
We adopted a three-pronged strategy to address the client’s challenges:
Organizational Design: We restructured the reporting hierarchy to align with the entire value stream. This involved comprehensive training to enhance the capabilities at each level.
Systems of Work: We introduced a robust system of work, which included: a. A visual escalation process to promptly identify and address issues on the line. b. Morning alignment meetings for all team members, followed by an afternoon “Check & Adjust” session to ensure actions were executed and the event was set up for success. c. A loss accounting system and a resolution program to assign dedicated corrective teams to tackle the most common issues.
Process Optimization: We conducted a thorough Value Stream Mapping exercise to identify losses across the value stream and implemented corrective actions accordingly.
Results:
Our interventions led to significant improvements in operational efficiency:
We achieved a 35% reduction in the Value Stream Cycle Time, enhancing the overall productivity.
The new converting line was operating at an impressive 90% OEE within just 18 weeks, marking a remarkable turnaround from the initial 32%.
This case study exemplifies our commitment to helping our clients overcome operational hurdles and achieve their efficiency goals. We continue to strive for excellence in delivering solutions that drive tangible results.
“We invested a ton in that machine and it wasn’t working anywhere near what we thought. We kept fixing problems to no result. Taking a step back and looking at it holistically helped. We set up the team for success everyday and only tackle the issues that truly matter.”
