A French group company's beverage factory in Huizhou (WCM world-class manufacturing)
Project background
The company is a wholly-owned subsidiary of a Fortune 500 group and the first factory independently invested and built by the group in China. It has a total investment of 500 million yuan, covers an area of 110000 square meters, and has 5-6 well-equipped production lines with an annual output of 700000 tons.
Core pain points
The factory is located in Longmen County. Due to its geographical location, it is difficult to retain management talents, and the domestic production equipment is outdated. The manufacturing process is unstable, and the factory faces dual challenges of quality and efficiency issues.
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Main consulting content
- Value stream analysis improvement and lean strategy deployment;
- Production line balance and layout optimization;
- Level scheduling and logistic improvement;
- Quick changeover;
- First time quality management;
- Autonomous maintenance and preventive maintenance;
- Continuous flow production;
- Establish a lean daily management model and specialized continuous improvement team activities, etc.
Effect and Benefit
- Efficiency: OEE increased by 15% (66% → 81%)
- Quality improvement: First pass rate increased by 60%, customer return rate increased by 81% (4.2% → 0.8%)
- Cost savings: 5.4 million yuan
- Talent Stability: Core Job Turnover Rate Reduced from 35% to 8%
- Industry benchmark: become a lean benchmark factory in the Asia Pacific region of the group, with domestic equipment efficiency comparable to imported equipment
- Establish a world-class 5S/visual factory
- By a pre positioned lean system layout, avoid the tens of millions of sunk costs of traditional factories that are built first and then renovated.
