Kaizen Institute - Success Story
Food - Dairy
Flow Management, Productive Mainentance
Client Profile
A market leader in manufacturing processed cheese and cream cheese in Romania.
Improvement Potential
- Delayed goods deliveries
- Frequent changeover
- Frequent equipment failures
- Constant pressure from customers in regards to the quality, failure in providing the requested quantities and delivery delays
Root Causes
- Wrong practices concerning production change (changeover)
- High changeover time
- Process and movement muda and Mura due to lack of standards
Our Approach
- Creating dedicated boards for parts and tools
- Implementing color coded visual management
- Optimization of the operating process
- Introducing changeover trolleys dedicated to equipment
- Introducing dedicated time management tools
- Investing in special lifting and transporting equipment
- Setting positions, labelling and standardization
- Introducing better gathering methods, standardized parts and Poka Yoke
- Introduction of specific workplace control tools
- Control and adjustments integrated blocks
Key Results
- Distance during changeover decreased by 48% (from 668 meters to 350 meters)
- Optimized methods and tools
- Zero changeover time (under 3 min.)
- Better preparation and organization, achieved with low cost investments and training of the operators
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