A multidisciplinary team worked on the plant reorganization project to enhance factory life. They created a brand-new welding section which, again, helped reduce turnaround in production time. They evaluated the actual machinery to optimize its use. They also established new ways of working by standardizing the warehouse section (pallet size, stock allocation, stock uniformization).
All these great changes were demanding but had a great impact for both business and people. Customer lead time dropped from 10 days to 2 days of production because of that material flow improvement. But the LEAN team was just getting started.
Step 2: Environment
Having in mind to evolve the LEAN mindset within the factory, the team came up with some environmental ideas. In 2017, the entire ventilation system was changed to enable temperature control across the factory. This major change first helped to provide a more comfortable climate for our employees through the seasons, while considerably reducing the break period needed. It was also beneficial for our gas consumption which is not insignificant.
Furthermore, switching boilers to electric energy was another important change in 2018 where we calculated a global reduction of 55% on our energy consumption without impacting our ratio. Drying oven, regular oven, heat treatment basins, central heating; all directly connected to natural gas central system. Needless to say, this generated a cost reduction to the factory as well as connecting us to environmental values that Signify has at heart.