Full factory transformation with Kaizen : Unga Limited

1
Discrete/ ProductionUnga Limited Full factory
transformation
Office, Stores Production Before Kaizen
Stores (Spare Finished Goods) After Kaizen
Zone Map - Finished Goods stores
Untidy Offices
Systematic arrangement - Stores
Poorly arranged Spare stores
Machines High Breakdown, Low Yield
Inventory control through Kanban
Office Production - After Kaizen
Results
Organized Storage File Folders
Floor markings, Improved Yield in machines
Improved Visual signs in Machines
2
Discrete/ ProductionMabati Rolling Mills Value
Stream Management
Process Before
OTIF through Batch Builder, Heijunka, Logistics
Board, Kanban Supermarket
Process After
Results
3
Discrete/ ProductionABM Full factory
transformation
Machines Before After Kaizen
Spares Distribution Store After Kaizen
Before
Management of Common tools
Spares Place for Everything, Everything in its
Place
Exposed Bearing balls
OEE Analysis Before Kaizen
Protected Bearing balls
Floor plan prepared to easily locate the items
After
Material Stores Before After Kaizen
Results
1) Materials arranged well 2) Stacks not too
high 3) Ease to count
Before
After
1) Materials arranged with no order. 2) Stacks
too high
Inventory controlled and replenishment is through
Kanban signals
4
Discrete/ AssemblyNAS In-flight Catering
Functional to Process Based Management
Process Before
Process After 2
One Common assembly Salad, Main Meal, Dessert,
Tray Set Equipment to create a one piece flow
process
5 different sub-assemblies (Salad, Main Meal,
Dessert, Tray Set, Equipment) to complete a
single meal
Process After 1
Results
3 sub-assemblies (Common Salad, Main Meal
Dessert, Tray Set, Equipment)
5
Discrete/ ProductionBlowplast Limited Full
factory transformation
Office Master Batch Stores
Finished Goods Store
Before
After
Before
Product identification is difficult
Planned production using PULL method
5S in Office
5S in Master batch Store
After
Before
Easy identification of products
Unplanned over production
Before
After
After
Kaizen in Machines Die storage
Results
Before
Die storage clearly labeled
After
Machine is hard to inspect for any abnormality
Machine modified and failures are now easy to
detect
6
Transactional/ AdministrationBlowplast Limited
Process Simplification
Cash Customers Before Kaizen
Customer complaints Before After
Cash Customers After Kaizen
Results
7
Discrete/ AssemblyFontana Productivity
improvement in harvesting flowers
Spaghetti Diagram Before Kaizen
MUDA reduced, Activities improved and
standardized, Rejections reduced
Before
After
Many stems leads to damage
Few stems ease to carry
Many stems Sizing difficult
Few stems Sizing easy
Spaghetti Diagram After Kaizen
Results
8
Discrete/ AssemblyLongonot Flow in pack house
Preliminary Analysis
New layout in the packing hall
Process wise cycle time in pack house
Spaghetti Diagram
Results
After
Before
9
Discrete/ AssemblyFinlays Veg. Processing
Packing Functional to Process Based Management
Process Before After
Spaghetti Chart After
Spaghetti Chart Before

• Crates pushed in the pack-house Use
  of trolleys

• Wrongly Placed brooms Correctly
  placed brooms

Work station After
Work station Before
Results
  Before Kaizen After Kaizen Improvement
Man power in Work station  17 11 35
Production in kg / man hour 6.2 7.1 14.5
Floor area (m2) 4.49 1.92 57
10
Thank You

• Crates pushed in the pack-house Use
  of trolleys

For More Information Please Visit Website
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