1.Understanding of current situation (GEMBA):

•Injection Molding Area: Experienced high scrap rates due to worn molds and extended downtime caused by unplanned equipment failures

•Shop Floor Management BASICs not followed

•Not effective Business Operating System in place

 

2.Critical Success Factors Implementation:

•War Room/Obeya (accountability room) implementation

•Designation of a single, empowered leader to oversee the improvement process

•Define and communicate specific Goals and KPIs

•Implement specific escalation rules

•Conduct daily reviews of execution progress in the War Room/Obeya

•Establish an international task force (German technicians) to restore injection molding machines to initial conditions. Define and execute a tooling refurbishment plan

•Ensure all commitments to customers are met and communicate any deviations in advance

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3.Accomplishments:

•Eliminated the need for air freight within 3 months.

•Manufacturing Operations returned to adherence with Operational Basics.

•Strong participation from all levels in all areas: Operators, Supervisors, Engineers, Managers, Directors and VPs.