Introduction:
In the ever-evolving landscape of the manufacturing industry, companies often seek innovative solutions to enhance efficiency and productivity.
El Arabbeya for Integrated Industries Co., trading as Unistar, stands as a beacon of success in this pursuit. Collaborating with Symbios Consulting Team, Unistar embarked on a transformative journey, implementing a year-long basic lean manufacturing project. This venture not only underscored Unistar's commitment to growth but also highlighted the prowess of the Symbios Consulting Team in driving organizational change.
Unistar' Evolution:
Established in 1997, Unistar started as a modest enterprise with 30 employees. Over the years, the company has expanded its footprint and now boasts a workforce of 300. Specializing in energy-saving lighting solutions, Unistar manufactures an extensive portfolio of products, including indoor and outdoor lighting solutions, as well as solar energy applications. The company's commitment to development set the stage for its collaboration with Symbios Consulting Team to deploy lean manufacturing practices.
Project Objectives:
The initial phase of the project focused on instilling a lean manufacturing culture within Unistar. Symbios Consulting Team conducted Lean Green Belt Training for engineers, supervisors, and operators, covering crucial topics such as 5S, value analysis, waste elimination, root cause analysis, and autonomous maintenance. The implementation of the Idea Management System facilitated the collection and tracking of kaizen ideas from all departments, reinforcing the principle of continuous improvement.
Key Initiatives:
Symbios Consulting Team strategically executed several initiatives to catalyze Unistar's lean transformation. The 5S program was introduced in a pilot area, later expanding throughout the entire factory with meticulous planning and oversight. A detailed Value Stream Mapping (VSM) analysis identified impediments to value flow, leading to the initiation of three lean projects. In the injection factory, the Team implemented a Total Productive Maintenance (TPM) program, starting with a pilot machine, encompassing autonomous maintenance and planned maintenance pillars.
Achievements and Savings:
The Lean Manufacturing Deployment project yielded remarkable results, encapsulated in the following key achievements:
- Lean Green Belt Training: 14 attendees.
- Completion of 4 project charters.
- Internal training for 170 operators with 100% participation.
- Reduction in changeover time from 4.3 hours to 1.25 hours for reflector production.
- 58% completion of Standard Operating Procedures (SOPs).
- Streamlining the HR hiring process, reducing time from 44 days to 16 days.
- Elimination of 96 obsolete molds and machines.
- Restoration of 3 injection machines.
- Significant productivity increases in various product categories, including corn drivers, driver panel 3c, and street lights.
- Lean Assessment Tool (LAT) score increased from 12.34% to 33.52%.
- Remarkable Return on Investment (ROI) of 242.5%.
Conclusion:
Unistar's lean manufacturing deployment, guided by the expertise of the Symbios Consulting Team, stands as a testament to the power of collaborative efforts in achieving operational excellence. The project not only resulted in substantial cost savings and increased productivity but also fostered a culture of continuous improvement within Unistar, positioning the company for sustained success in the dynamic manufacturing landscape.
