Case Study: Enhancing Efficiency in Graphics and Label Changeover
Challenge
Addressing changeover times and quality issues.
As a quality manager new to the can-making industry, it was evident that the focus on production overshadowed the importance of quality, particularly in graphics. The industry's shift towards producing a wider variety of labels in smaller quantities presented a unique challenge: managing frequent label changes without sacrificing quality or efficiency.
Process
Implementing Expert-Led Training and Improved Practices
Recognizing the need for enhanced training, a contract with a Graphics Expert was established. This move aimed to bridge the gap in technical knowledge and appreciation for the daily challenges faced by operators. Off-shift training sessions were organized for Deco-Maintainers, Quality, and Production Supervision teams. These sessions were conducted in a classroom setting, away from the production floor, to facilitate better knowledge transfer and engagement.
Solution
Strategic training and employee engagement.
The training program was designed to provide operators with a deeper technical understanding of printer and ink setup requirements. It also helped management recognize various skill levels among employees and identify future training needs. Importantly, the training fostered a sense of unity between operational and quality personnel, aligning them towards common goals.
Outcome
Improvements in efficiency and customer satisfaction.
The initiative led to a 25% reduction in changeover times and a 10-15% increase in finished product output. Additionally, there was a remarkable 66% decrease in customer complaints and a reduction in spoilage by over 40%. These improvements not only enhanced customer relations and loyalty but also established a model for effective employee engagement. This model has since been replicated across various can production processes, yielding similar positive financial and cultural results and fostering better teamwork.