International home care product manufacturer needed to improve capacity on critical bottling line

The company

The company’s vision is to become a global leader in brands and technologies. They hold globally leading market positions both in the consumer and the industrial sector. The company is organized into three globally operating business units: Laundry & Home Care, Beauty Care and Adhesive Technologies. The Dax-30 company is headquartered in Germany, and is proud of its almost 50,000 employees from more than 120 nations worldwide.

Their needs

The company wanted to increase output in one of their most important bottling plants. The specific production lines in question were responsible for 30% of the plant’s total output. They produced two different products weekly with changeovers between products consuming 20% of the available time. They wanted to maximize output to delay building another line. 

How we helped

Paloma Consulting trained and supported our client through a 1 week Rapid Improvement Event (RIE). Training to a selected team of operators was delivered in the tools of waste identification, process mapping and other set-up reduction measures and improvement techniques. The whole process was videoed and analysed remotely by the team. Immediate improvements were agreed and made in the week. Twenty nine other opportunities were identified and potential solutions generated for further improvement. With Paloma’s help the team members presented the results and recommendations to the executive management team.

Benefits

The original changeover process was reduced from 8 hours to 4 hours (50% reduction) leading to 16 hours of additional production time yielding an additional 12.5 million bottles per annum in capacity. The additional further improvements were approved by management and yielded a further 50% reduction in changeover time generating another 6.25 million bottles per annum of capacity.

 

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