Project Objectives
The production facility in Lithuania was underperforming after relocating to a new site, with efficiency stuck at 55% of its expected capacity. The company needed a clear understanding of why the transition had caused such operational challenges and requested a deep dive into their production processes.
Over three weeks on-site, we rolled up our sleeves and went step by step through every process, mapping workflows and identifying trouble spots. This included direct observation of tasks, discussions with staff and a detailed review of the technology in use.
Key Observations
• Workflow imbalance: The gluing area was consistently overloaded, acting as a bottleneck, while other departments had underused resources.
• Technology mismatches: Advanced machinery was being used for simple tasks, while fully automated systems were left idle due to mismanagement.
• Complexity in processes: Flows were unnecessarily intricate, creating delays and inefficiencies.
• Wasted resources: Significant time, material, and effort were being lost due to poor coordination and lack of structure.
Using value stream mapping, we restructured the processes for simplicity and efficiency. This meant balancing workloads, aligning tasks with the right resources and prioritizing flow to keep production moving without hiccups.
Key Achievements
• Reshaped workflows to simplify processes and balance workloads across departments.
• Reduced fabric waste by €150,000annually.
• Identified and provided solutions for 30+ hidden quality and safety issues.
• Optimized the use of technology, ensuring advanced systems were utilized where they added the most value.
This hands-on approach addressed critical inefficiencies and provided practical, implementable solutions to improve the overall flow and output of the plant.
