Lean Accomplishments
Kaizen results
The Kaizen results largely depend on the team members and the consultant or coach and the way they interact together. I like to teach the team members to how to see the Lean opportunities so they can fulfill the Kaizen targets
100% On-Time-Delivery
30% Reduction in RM Inventory
50% Reduction in WIP Inventory
20% Reduction in FG Inventory
30% Productivity Increase
50% Reduction in Scrap & Rework
90% Reduction in change over time
50% Reduction in manufacturing space
50% Reduction in Warehouse space
50% Increase in Uptime
Injection Moulding Setup Reduction
Mould set up
from 4h / set up => 6 min
from 3 set ups / day => 20 set ups / day
Color change-over
from 1h / set up => 7 min
from 5 set ups / day => 40 set ups / day
Lever arch file binder production Setup Reduction
Size setup from 2h to 9 min
Color change setup 1h to 3min
School exercise book production Setup Reduction
Size/format setup from 3h to 40 min 1 Kaizen
Staple band line production Setup reduction
Wire/format change setup from 24h to 40min
Ring binder mechanism assembly line Setup Reduction
Size/format setup from 22h to 44min
Film coating Setup Reduction
Size/format setup from 3.5h to 55min
Line design/ 3P/ Kaizen results
Plastic Staple gun assembly line 3P
Before Kaizen cycle time 26 sec 9 heads
After Kaizen cycle time 24 sec 3 heads
Digital Camera Assembly Line Standard Work
Before Kaizen 30/ day 11 heads
After Kaizen 35/ day 7 heads
White Board production 3P
Before Kaizen 2 heads Assy/cure time 24h
After Kaizen 0.5 heads Assy/cure time 35min
Raw Material / Finished Goods Pull System
Reduced Leadtime by 30% to 40%
Improve Service Level by 27%
Improve Inventory turns from 2.1 to 19+
Reduced Inventory by 73%
