Lean Transformation Program (LTP)
allowed NG’s metal sorting plant reduce throughput time by 80%, inventory by 25%, and double-handing by 80% in just 1.8 years. The site matured during this period from Iron to Bronze level. Following the program, the team applied 5S principles to structure the plant, defined best practices for metal handling, developed quality standards for metal separation to better meet the requirements of downstream customers, and implemented a visual Performance Management System (PMS). The extra effort paid off: iron throughput speed increased 5x (receiving-processing-selling), slow-moving inventory was reduced to 1/5 from 20% to 4%, the required space shrunk by 25% (from 8,000 to 6,000 sqm), organizational level 5S increased from 0.8 to 3.8 overall, abnormalities (double-handling and inventory-overflows) fell from 25% to 5%, and availability of the critical metal press increased from 69% to 88% through targeted maintenance.