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Manufacturing >> Case Studies >> Paper-Lean Manufacturing
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Implementation of Lean Manufacturing at a Paper Manufacturer |
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Client Situation:
- A loss making Paper manufacturing facility with a strength of 300 employees and 300 contract people
- Paper losses, breakdowns and customer complaints were high
- Morale of people was low
- Top management mandate was to turn around the unit , make it visual and set up robust production systems for survival
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ECS Approach:
- Intervention designed on Lean Manufacturing with TPM and Six Sigma platform
- 8 Process teams,36 Operating teams were formed and they performed daily management
- 5 Capability teams were launched in the areas of Order Fulfillment, Planned Maintenance
- Six Sigma projects launched in the areas of Paper loss,downtime reduction, product quality improvement
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Results:
Lean Metrics |
Before |
After |
| Paper Waste Repulping (%) |
2.94 |
2.01 |
| Finishing Paper Loss (%) |
9.6 |
8.5 |
| Top Liner Consumption (kgs/ton) |
250 |
230 |
| Power Consumption in kwh/mt |
580 |
525 |
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Contact: manufacturing@ecs-limited.com |
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CHENNAI |
ECS Limited
1st Floor, Mootha Center
New Number 23
(Old Number 9/1)
Kodambakkam High Road
Nungambakkam,
Chennai - 600 034
Tel: 91-44-52123481, 52123471,
Fax:91-44-52122190
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DELHI |
ECS Limited
804, Signature Towers,
Tower A, South City I,
Gurgaon - 122001, Haryana
Ph: 91 124 2383301/02, 2383725/28, 2382409
Fax:91 124 2383295
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MUMBAI |
ECS Limited
2A, Wing A, 8th Floor,
Prism towers, Mindspace,
Goregaon (West),
Mumbai, INDIA 400062
Tel: 91-22-40074600, 40033400 / 1,
Fax: 91-22-40074700
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BANGLORE |
ECS Limited
29/30, Kasturba Road Cross,
Bangalore,
India - 560 001
Tel: 91-80-22270820, 22277153
Fax:91-80-22271720
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DUBAI |
ECS Limited
M11, Business Avenue,
Sheikh Rashid Road ,
Deira, Dubai
P O Box 112466
Tel:+971-50-3414048/ 8443039
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