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Productivity improved by 22% applying Lean principles

Reduction in stoppages: 90%
Increase in productivity: 22%

The challenge

In our Czech facility of Trinec, a production cell dedicated to insulating sleeve application, was facing an increase in work volume and price pressure from customers. The cell struggled to meet the growing demand in production as it was only able to produce 20 parts every 40 minutes, partly due to a required stoppage of ten minutes at the end of each pattern. Capacity was limited to 176 parts per shift.

Our solution

Following the Group Standardised Work training deployed in 2014, the Trinec team applied Lean principles to the workplace, reorganising the two workstations to reduce risk, remove unnecessary movement and improve ergonomics.

The benefits

These Lean working practices have reduced stoppage time to change patterns by nine minutes (a 90% reduction), increasing productivity by 22% to 215 parts per shift. The site is now able to meet the increasing demands of its customers with the same number of employees.