PPM Becomes a "Lean Manufacturing" Facility.
August 26, 2004
On June 2, 2004, Pittsburgh Plastics launched a 13-week program on Lean Manufacturing. Lean Manufacturing starts with various studies, data collection and flow analysis of all aspects of a manufacturing facility. It is critical to collect enough data and analysis to optimize each process based on facts and not opinions. The amount of data required depends on the nature and condition of each manufacturing process.
The discipline of project management can make a difference to lean implementation efforts. In the beginning, our focus was on three main processes in our facility. However, during the third week, lean manufacturing EXPLODED into every aspect of our manufacturing facility. Employees became interested in helping to improve productivity, workflow and the power to eliminate waste! Jim Zona, Chairman and CEO, said, "It is like getting poison ivy. Once you have it, it is hard to get rid of it! It is very contagious and has definitely spread throughout our entire plant."
By adopting the Lean principles we are eliminating waste and continuously improving current systems, processes and informational flow. By streamlining production processes we significantly reduce cycle times, decrease inventories, lower costs and increase customer satisfaction.
During the lean program 5-S inspections are performed on a monthly basis. A 5-S inspection involves a team of employees evaluating and monitoring a specific area utilizing a standardized form. There are five main points of concentration with Lean: Sort, Shine, Set In Order, Standardize and Sustain! By optimizing 5-S monitoring we maintain and improve working conditions and manufacturing processes. It truly is a "TEAM EFFORT" by all employees of Pittsburgh Plastics.
ince lean manufacturing started at PPM, we can already see a significant improvement in productivity. The results are overwhelming. We, as a company, now know what it means to be qualified as a "Lean Manufacturer"!
