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Full factory transformation with Kaizen : Unga Limited

Kaizen Institute Have Implimented lean Factory Transformation at unga limited.kaizen diagnose problems,create awareness,draw roadmaps,lead implementation,

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Full factory transformation with Kaizen : Unga Limited

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  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 Poorly arranged Spare stores Systematic arrangement - 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 Results Process After 1 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 After Before 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 After Before 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 Results Spaghetti Diagram – After Kaizen

  8. Discrete/ AssemblyLongonot: Flow in pack house Preliminary Analysis New layout in the packing hall Process wise cycle time in pack house Results Spaghetti Diagram 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 Results Work station Before

  10. Thank You For More Information Please Visit Website : http://in.kaizen.com E mail : india@kaizen.com Tel : +91 79 2640 7750 • Crates pushed in the pack-house Use of trolleys

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