In a previous blog post, we described the initial steps of our Lean Journey. This entailed using Value Stream Mapping (VSM) to study our entire production process, creating a Current State Map to identify improvement opportunities and developing a streamlined Future State Map to define how we would like our process to work in the future.
Once we successfully completed our Value Stream Mapping, it was time to test our plan using one of our envelope converters. We began by observing the envelope conversion procedures and then conducted a series of trials to gather baseline data on machine set-up and operation, remove obvious waste, and establish a new sequence of events for machine set-up and operation.
The initial findings were very exciting. Our new procedures reduced set-up time by 55%; exceeding the goals set for the team. In addition, the distance traveled by our adjusters during set-up was reduced by 67%. Our Lean initiatives also resulted in several safety and ergonomic improvements.
Still, the lingering question remains: can these positive outcomes be replicated along other areas of our production stream? Stay tuned for more updates on our Lean Journey.
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