Engineered plastics manufacturer achieves visual improvements

Redco Ltd

Key Achievements

• 10% Improvement machine efficiencies
• 30% Increase in turnover
• 20% increase in GVA

MAS saw a way of achieving the objectives set by Redco by the introduction of Visual Planning techniques supported by a programme of Lean Manufacturing.

The project was launched by introductory training in the following:

• Lean Awareness and the 7 Wastes
• OEE measurement and 5S/TPM principles
• SMED Principles

From this point a parallel process was adopted covering Scheduling and Planning using Process Mapping techniques to identify non value adding activities.

From this approach a significant programme of continuous improvement was implemented:

On Time In Full Metric established and being tracked monthly, and using 3 month Rolling Average

Turnover/Labour Hour Metric. Established for Precision and Warehouse.

Visible Scheduling and Planning Boards In Place. Using Job Cards format which tracks progress of each job through the shop and through Warehouse, Packing and Despatch

Set Up Studies Completed.

From the studies carried out we identified a change needed in the costing process:

• Separate Programming time
• Separate Set Up Time and record improvements
• Record Actual run times and record improvements

The project approach supported Redco’s decision to procure and implement an ERP System. Enabling the introduction of key modules within the selected system.

• Customer Relationship Management (CRM)
• Scheduling and Planning
• Shop Floor Data Capture
• Estimating and cost tracking

As an ongoing improvement project off line programming is now being investigated, which will reduce set up time by up to 60%.