Improving manufacturing process with Lean (use case insights)
Introduction
The last 50 years has seen major push towards effectiveness, which includes but not limited to reducing defects and waste. High costs associated with waste compelled a lot of companies to relook at their processes.
To address the high levels of waste, a number of companies adopted Lean.
In this specific use case, I highlight insights from the approach I took and findings from efforts to improve the packaging process of No-name company. The departments relevant to this use case are Filling, Sealing, and Packaging.
Understanding the Challenges
Approximately a third of the products had defects and failed the quality control checks, resulting in re-work and scrap.
- A product has approximately 66% chance of going through the process without defects.
- An overview of the overall quantity of defects seems to show a rising trend. However, drilling down into 2022 shows a rising trend from June to October.
- The most significant type of defect is the overfilling of bottles.
Prioritization
To be added
Addressing the Problem
To be added