In the implementation phase, which follows next, the steps defined are put into practice. In regular team meetings, the success of the programme stages is reviewed on an ongoing basis. The customer’s employees are given comprehensive training in using the data generated to identify opportunities for improvements, and to initiate appropriate measures. This ensures that once the external guidance offered by SIG Combibloc has ceased to apply, customers are able to continue optimising, independently and sustainably.
The Operational Excellence Consulting programme covers all areas that relate to the manufacturing process. The programme focuses on the areas with the greatest potential for optimisation. In addition to equipment effectiveness, these areas include employee productivity and resource utilisation − the goal is to generate continuous and sustainable improvement.
To increase equipment effectiveness, firstly, planned machine downtimes (for instance, to carry out cleaning processes) can be standardised and optimised. The reasons for unplanned downtimes are also analysed and, where possible, reduced.
Another important consideration is employee productivity. The first step is a status analysis in respect of the company’s organisational structure and workflow management, with the aim of then optimally planning human resource allocation based on these findings. Reference values from best-practice examples are taken as the benchmark for identifying and implementing potentials. In addition, targeted further training and the transfer of more responsibility can also contribute to improving the employees’ level of qualification and increase their commitment.
In terms of resource utilisation, a detailed analysis of key consumables offers additional possibilities for improvement. Handling and actual consumption of selected materials used in the production process are determined and compared against examples of best practice. Deviations from these values can thus undergo targeted analysis and the use of resources can be improved as a consequence. The use of existing equipment is analysed on the same basis. In this case, it is important to analyse, for example, whether the individual components in the line fit together perfectly to ensure the best possible and most efficient production.
To ensure sustainable optimisation in the production process, a system for organising continuous improvement is devised and implemented. The involvement of the machine operators in the improvement process, and the target-oriented management of employees within the production process are essential aspects in maintaining this system. Another important consideration is the development of a meetings and communication strategy. This includes defining which topics will be discussed and handled in what timeframes and in which groups. Precisely defined shift handovers are also vital in this respect.
Tobias Hammeke: “The Operational Excellence Consulting programme focuses squarely on improving operational performance and lowering production costs. With successful implementation of an OEC project, the investment pays off for the customer within a year”.
