5S and Basic Lean Implementation at Al Munif Pipes in cooperation with the Industrial Modernization Center IMC.
Starting in May 2022, we’ve had the wonderful opportunity to work alongside the Munif factory for pipes in
Egypt, implementing a successful 5S, basic lean principles, and awareness program that lasted for 6 months.
Al-Munif for pipe manufacturing is a key player in the pipe manufacturing industry, providing a versatile range of PVC pipes utilized for housing and Infrastructures intended for use on a wide variety of applications, ranging from drinking water to Sewage, Cooling, Irrigation, and telecommunications.
Having been backed by a team that was very supportive and eager to improve, current state analysis was carried out to gain a bigger picture of the current hotspot areas and any rooms available for improvement, new challenges were then set out to different departments with a special focus on involving everyone in the team. Hours of training were then provided by Symbios and along with incredible hard work and persistence from the team, incredible results were yielded, ranging from 10% to as much as 57% improvement in the 5S audit for some departments, Inventory area savings reached approximately 90 m2, Time savings in different departments were averaged at a 68% increase, Different maintenance methodologies were also applied yielding an impressive 90% reduction in breakdowns and Oil, Air, and PVC Resin leakages as well as Labour costs and finally, Key improvements in the overall safety and cultural awareness of the staff were observed. Consequently, a detailed cost analysis was done, and the ROI was calculated at 3.11.
http://www.imc-egypt.org/index.php/ar/
https://symbios-consulting.com/
Watch the full journey: https://www.youtube.com/watch?v=ViXoX2g-0Bk&t=13s
