Manufacturer of uPVC windows

This project was divided into several stages, with each stage being implemented at the workstations.

1. Stage I: Process audit 

   • This project was divided into several stages, with each stage being implemented at the workstations.
   • review core processes in the company
   • snapshot study
   • define strengths and weaknesses in the organization
   • analyze flow, process indicators and identify bottlenecks

2. Stage II: Implementation of 5S rules

   • conduct a workshop in a pilot area
   • develop 5S standards (map legend, a plan and a cleaning schedule of the pilot area)
   • foremen and leaders participating in the workshop conducted an employee briefing regarding 5S 
   • set up a schedule of implementation in the remaining production areas
   • implement standards of conducting 5S audits in the production area

3. Stage III: Implementation of SFM in the production area 

   • implement regular operational meetings on two levels: SFM 1 and SFM 2
   • implement process indicators that the meeting is based on
   • participants should define tasks in the event of failure of achieving set goals
   • clear division of responsibility and transparency of decision-making processes
4. Stage IV: Solving problems with order picking using the Problem Solving method
   
   
   • conduct workshops in accordance with the DMAIC method
   • conduct workshops in accordance with the DMAIC method
   • precise description of a problem and the scale of inconsistencies
   • conduct problem analysis using the Ishikawa Diagram and 5Whyestablish an action plan
   • implement problem monitoring using SFM 1 indicator

5. Stage V: Process management skills, balance 

   
   
   • make leaders and foremen aware of their role and tasks in the process 
   • balance human resources – according to the needs and stage of the process
   • process analysis in terms of quality – 3P principle
   • process flow analysis based on current results and stock location 
   • shift handover