• Home
  • About
    • Company Profile
    • Contact Leanmap
    • Engagement Model
    • Experts on Demand
    • Improvement Process
  • Consulting
    • Operations Diagnostics
    • Lean Transformation
    • Quality Excellence
    • Cost Reduction
  • Calculator
    • Labor Cost Savings
    • Equipment Effectiveness
    • Non-Quality Cost Savings
  • Audits
    • Operations Health Check
    • Lean Factory Audit
    • Lean Office Audit
    • Lean Certification
  • Academy
    • Online Certification
    • Agile Lean Six Sigma
    • Strategy Deployment
    • Problem Solving Skills
    • Cost Reduction Strategies
    • Performance Management
  • Store
    • Products & Services
    • Membership Options
  • News
  • Login
  • My Account
  • en English
    ar Arabicbg Bulgarianzh-CN Chinese (Simplified)cs Czechda Danishnl Dutchen Englishfi Finnishfr Frenchde Germanel Greekhi Hindihu Hungarianit Italianja Japaneseko Koreanno Norwegianpl Polishpt Portuguesero Romanianru Russianes Spanishsv Swedishtr Turkish

Plastic Production: Increasing Yield, Flow, Resilience during Pandemic

December 30, 2020

Trioplast, one of Europe's leading manufacturer of polyethylene film

for cost-effective packaging solutions embarked on a systematic Lean rollout in 2018 to transform its operations. Over the course of two years, the two focus factories in France and Denmark matured to Silver-level, attaining a score of 3.2 and 3.0 respectively on the five-point benchmarking scale. As the global pandemic was unfolding in 2020, the newly-implemented standards and systems demonstrated the value of the Lean process, helping the team to not only adapt and maintain output levels, but also step up quality and productivity, despite strong “headwinds” and absenteeism levels. Basic Lean at its best.

Lean Factory Trioplast France
Lean Factory Trioplast France
Lean Team Trioplast France
Lean Team Trioplast France
Lean Team Trioplast Denmark
Lean Team Trioplast Denmark
Lean Factory Trioplast Denmark
Lean Factory Trioplast Denmark

Program Brief

  • Type: Lean Transformation
  • Client: Trioplast
  • Role: Navigator & Trainer
  • Period: 06/2018-12/2020
  • Scope: 4 focus factories

Impact France 2020

  • Flow: +29%
  • Availability: +35%
  • Quality: +11%
  • Standards: +365
  • Lean Projects: +17

Impact Denmark 2020

  • Flow: +21%
  • Availability: +13%
  • Quality: +6.5%
  • Standards: +147
  • Lean Projects: +12

What doe those numbers actually mean? The reduction of planned and unplanned stoppages increased the flow of production, gaining throughput as a result. The reduction of breakdowns through productive maintenance increased the availability of extruders and other key equipment. The improvement of process capability (sigma) reduced variability, which led to higher quality and lower scrap levels. The standardization of critical and common processes reduced effort and variability, resulting in higher labor efficiency. These results were achieved with 10-20 Lean improvement projects per factory, implemented during 2020. Well done, team France and Denmark. We are proud of you!

Transform Plastic Production
Share on facebook
Share on twitter
Share on linkedin
Post Views: 381

Filed Under: Certifications | Bronze | Silver | Gold Tagged With: Lean Award, Lean Certification, Silver, Trioplast

Reader Interactions

Leave a Reply Cancel reply

Your email address will not be published. Required fields are marked *

Footer

We help our clients boost performance levels by solving operational constraints, rationalizing processes, and bringing mission-critical projects back on track – Navigating to Results.

News

  • Change Management: The 7 Success Factors and 7 Failure Reasons...

    Jan 10th, 2021

  • Lean Team Trioplast France

    Plastic Production: Increasing Yield, Flow, Resilience during Pandemic...

    Dec 30th, 2020

  • Root Cause Analysis: Using Logic Trees to Solve Critical and Complex Problems...

    Dec 3rd, 2020

Categories

  • Certifications | Bronze | Silver | Gold
  • Engagements | Programs | Projects
  • Insights | Observations | Learnings
  • Training | Yellow | Green | Black Belt

SERVICES

  • Assess Operations
  • Download Tools
  • Get Certified

Copyright © 2005-2021 Leanmap | Privacy | Terms | Contact | Feedback