Download - Storyboard packaging costs APD1
Define Measure
ControlAnalyze
Reduction in Secondary Packaging costs storyboard – Robert Caldwell
Scope and goals for the project defined in the charter
Improve• Reduced customer packing specs from 147 to 52. • Developed a packing spec template for future use by customers. • Carried out a mini kaizen on the floor area to help combat wasted cardboard etc. • Communicated new specs to floor staff
Measurement consisted of:•Number of current packing specs (147).•€ being spent on cardboard and plastic.•Breakdown of costs per pallet e.g. Kraft finished pallet vs. mars finished pallet. •Volumes of cardboard being disposed of or wasted.
Difficulty with the number of packing specs need to reduce from 147 specs
• We compared volumes of pallets being dispatched versus actual cost of packaging the pallet. • We analysed the customer specs to evaluate their relevance and actual needs.
• Developed new Sop's for floor staff using the new packing specs• Monthly auditing of luas line area to ensure floor is being kept tidy and cardboard is not being wasted on site.
CELEBRATE
• We streamlined all the specs and were able to reduce them from 147 to 52 or 1 per site/ customer, we reduced the amount of cardboard in the specs
Validated€50K
Define Measure
ControlAnalyze
Green belt ~ Mislabelling storyboard ~ Robert Caldwell
Improve
Project defined by team;• Mislabelled lanes on coils• Mislabelled pallets• Impact on customer traceability• Possibility of losing significant business from mars due to complaints
Used root cause analysis and 5 why’s to find out the reason behind mislabellingWe discovered that due to a computer error that too many labels were being printed out and were being mixed up.
Involved slitting operatives to gain tribal knowledge of the system
• We reviewed who had access to end pallets• Implemented a new mini atms label to simplify things• ordered more aggressive labels
Mini Kaizen on area led to improvements
We developed a control plan to include:• Monthly auditing for first 3 months after project ended• Daily spot checks of pallets to ensure mini atms label is being used
We made a system change to atms to allow it to only print out finished pallet labels by 1 personThis reduced the number of labels at packaging
Due to new issues arising towards the end of 2007 we reviewed the project and made some more system changes, we now have a new bay for dispatch which again reduces chances of mislabelling
Mislabelling Complaints
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2007REVIEWED PROJECT
25K VALIDATED