Project Components
The project assessed the current state through value stream mapping, identified improvement opportunities, applied 5S and visual management, and created standard operating procedures. It developed production and quality planning systems, implemented TPM and OEE measurement, and trained engineers in Kaizen and problem solving.
A. The Challenge
ABCO Plastics needed to streamline operations, reduce waste, and improve productivity and quality. Processes were undocumented, maintenance practices reactive and staff lacked Kaizen skills.
B. Our Solution
We mapped current and future state value streams, introduced 5S and visual management, created SOPs and improvement initiatives, implemented TPM and OEE calculations, and provided training in Kaizen methodologies and problem-solving techniques.
C. Key Achievements
The project delivered a complete improvement plan with measurable increases in quality and productivity and reductions in cost. Engineers gained practical Kaizen skills, and standardised procedures and maintenance practices were institutionalised.
Project Particulars
Client:
ABCO United for Plastics & Chemicals
Start Date:
2019
End Date:
2020
Service Area:
Quality and Institutional Excellence
Client Sector:
Industry
Duration:
Sixteen months and Fifteen days
Client URL:
Status:
Completed