WCM/ Lean Mfg. System Project of worldwide infant formula brand (Shanghai)
Project background
This dairy company entered the Chinese market in 1995. Then it is one of the main infant milk powder brands in the Asia-Pacific region. After the Sanlu milk powder incident in 2009, the government imposed various monitoring and control requirements on all milk powder companies. This brand was also compelled to conduct 60 or more mandatory inspections for each batch of products within 24 hours. The demand for imported high-quality milk powder in the Chinese market has increased dramatically, presenting the company with unprecedented opportunities and challenges. Shanghai factory launched lean manufacturing system WCM in 2010, Through a three-year implementation and continuous improvement of the manufacturing system and became their global benchmarking factory.
Major content
Carry out a series of workshops, including VSM, KPI system, line balancing and layout optimization, level scheduling, quick changeover, first-time quality management, TPM, material pull system, information flow optimization, continuous flow production, lean laboratory and lean daily management and CI group projects, etc.
Effect and Benefit
- One-third of warehouse space saved, cost saved 1.72 million yuan per year.
- Testing lead time was reduced from 7 to 5 days, with an efficiency increase of 12%. Procurement lead time reduced from 30 to 3 days, direct saving 2 million yuan.
- Production capacity improved by 30%, OE was raised fr. 75% to 90%, with an expected direct saving of 4 million yuan.
- A group of internal improvement experts were trained and developed, creating a favorable continuous improvement working environment and enhancing employee satisfaction.
