Lean Manufacturing Empowers Staff: Productivity Up, Absenteeism Down
This rapidly growing food processing business manufactures dressings, sauces, mayonnaises and desserts for airlines, hotels, cafes and restaurants, and for gourmet delicatessens and select supermarkets in Australia and South East Asia.
The company is continually looking to expand into new market segments and to improve production processes.
This is a highly seasonal business and during peak production in December-January additional shifts have been needed to meet demand.
The company engaged Corporate Partners to initiate Lean in the workplace. Corporate Partners introduced a suite of Lean Manufacturing tools including 5S, Value Stream Mapping, Visual Workplace Management and Mini Business Teams.
Mini Business Teams and Value Stream Mapping are vital Lean Manufacturing tools and are the cornerstone of successful business transformation. Teams are equipped with the tools and skills to develop and achieve their mini business targets. This team approach truly engages employees in the business improvement process and has everyone working together towards achieving workplace excellence.
Lean Manufacturing Results
The introduction of Lean Manufacturing has improved productivity with an increase in output-per-employee of 5.7%. Peak demand is now being met without an additional night shift.
Delivery in Full on Time and in Specification has improved by 2%.
The Mini Business Teams are solving problems with greater speed and contributing improvement suggestions. Employees are more engaged and empowered and absenteeism has gone down by 17.7%.
An initial focus on safety resulted in a 129% increase in reported incidents, however the increase in reporting has resulted in a reduction in lost time to injuries and the company has saved $265,000 in workers compensation premiums.
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