In the world of modern manufacturing, every step that can be taken to reduce waste and create a well-coordinated, dynamic flow in a production run feels like scoring a spectacular winning goal.
There are many areas in a injection molding factory that, given the chance, could allow wastage to slip into the mix. By exploring and understanding each of the risk zones, it's perfectly possible for a six sigma professional to react and reduce.
The first considerable area to consider is staffing. By having underutilized staff on your team and multiple layers of form-filling management, there is an abhorrent waste of paid hours, all of which impact the company's P&L, and in turn the final price to the buyer. A flatter, more pancake structure not only saves on cost, but also typically results in faults being discovered more quickly, and a more highly motivated workforce. Both of which are substantial benefits.
Another more granular section to look at is the reduction of defects in the finished product. Aside from obvious material waste in having to re-run the batch if one is discovered, the knock-on effect goes much further as any product that is delivered and rejected results in wasted transport costs, and most worryingly of all, an unhappy customer.
The same applies for over-production or or-ordering raw materials. Both incur incremental storage costs, which are wasteful in monetary terms, but also in physical space which could be better utilized for additional machinery.
Finally, a well-coordinated and designed production site will see staff members using clearly defined routes that avoid waiting for secondary actions to be completed and reduce the amount of time and distance any individual part takes to move from one department to another. Cutting the distance or positioning the end stages of one section in the right direction to the subsequent section may save only a matter of minutes each time, but annually that saving is significantly more than you first expect.
One company that is obsessed with cutting waste in every aspect of their business is Adis Tachov. Led by two hands-on six-sigma black belts and with a host of other lean experts in the team, ensuring a perfectly smooth operation comes second nature. With a flat org chart, well-thought-out and designed layouts, and multiple quality control systems and processes to ensure perfection, it’s this attention to detail and approach that explains why they are regarded as one of the best plastic companies in Europe.
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