Process Improvement Workshop

Following a ukfirst Process Improvement Workshop, Primafoam (part of Vitafoam) have achieved a vast improvement in the flow of information and materials throughout the entire business. Their ever expanding product range now spans 35,000, which is increasing by 10% per annum.

By focusing on the basis of “Right First Time” there has been a 46% reduction in non-conformance work which has had a direct impact on the overall profitability.

Objectives
-  To improve adherence to lead time
-  To focus on the organisation and clarity of workload
-  To achieve a higher level of customer satisfaction
-  To improve work flow and stock control processes

Approach
Ukfirst Master Engineer, Bruce Lovell worked with the Primafoam improvement team to analyse the key issues faced and operational constraints. Value added activities were highlighted and separated from non value added operations.

Tools and Techniques
A pull system was introduced to control the entire production process.
A 7 waste activity focused on the kitting process by identifying and categorising the waste elements.

Results
The wastes identified were eliminated by the introduction of kitting tables which reduced bending and stretching. Frequently used tools and parts were stored within the kitting area to increase efficiency. These actions combined stabilised, maintained and improved the working environment through quality, cost and delivery.

Client Feedback
“Following the input of ukfirst’s Master Engineer, we now think together as a team working toward the same goal, rather than as separate entities in the production process.”

Andy Corbett- General Manager, Primafoam

For further information on Vitafoam, visit www.vitafoam.co.uk