OEE Improvement and Defects Reduction through Lean Six Sigma

A leading plastic packaging disposables manufacturing in UAE. Introduction of integrated Lean Six Sigma Kaizen as a Operational excellence Strategy and create a road map and implementation for 2 factories.

Customized training on Lean Six sigma at all the levels, involvement of operators in Daily work management, Focus on getting first time right. Rewards and recognition, More focus on 5 S , TPM and Kaizen systemization.

Integrated lean Six sigma implementation at a food grade plastic disposable products mfg. co. at UAE

Client:

A leading plastic packaging disposables manufacturing in UAE.

Challenge:

Introduction of integrated Lean Six Sigma Kaizen as a Operational excellence Strategy and create a road map and implementation for 2 factories.

Project:

Identify key themes and important improvement projects and mobilize resources and support for the whole initiative for long term.

Approach:

Lean Six sigma approach for problem solving which includes Assessment of process and activity, OEE of critical lines , gap assessment, yields, prioritization according to criticality, mistake proofing of the overall manufacturing process.

Activities:

process mapping and capability analysis, introduction of DMAIC approach and Tollgate Reviews, processes, training and ongoing coaching.

Results and financial returns:

1. Improved GE / OEE from average 60% to 70 % for all the critical lines.
2. COPQ reduction $4 millions per annum.

What makes this a “Lean Six Sigma” project?

3. Improvement of OEE.
4. Involvement of Employees in Kaizen initiatives.
5. Intensive use of process metrics and basic 7 QC tools methods.

The Lean Six sigma toolkit:

Vale Stream mapping, Process capability analysis and metrics, cause and effect analysis, Pareto analysis, OEE 9 step process for improvement, Kaizen, CFT approach, Balanced score card.

How did we engage people and drive change?

Customized training on Lean Six sigma at all the levels, involvement of operators in Daily work. management, Focus on getting first time right. Rewards and recognition, More focus on 5 S , TPM and Kaizen systemization.

Gazelles added value:

Extensive experience in Manufacturing Process Improvement initiatives by providing customized solutions for Cultural and technical challenges.