Situation:

Business directors of 7 manufacturing sites across 3 global regions initiated a project to standardize operating best practices for equipment that existed in all of the sites. Operating practices varied across each site and translated to a significant gap in cycle time to perform work and/or operate the equipment across sites and shifts (work schedules). This disparity brought about a significant loss in performance of the operating unit and created higher cost and poor product quality.

Solution:

  • Identify all potential equipment that could be targeted for standardized operating practices.
  • Evaluate level of performance and factors impacting cost, cycle time, etc.
  • Identify optimum process guidelines, conditions, and processes for operation.
  • Create a standardized operating best practice for each piece of equipment within the scope of the project.
  • Create a managing system to sustain the solution and keep it evergreen.
  • Create an implementation and communication plan.

Results:

15 new standardized operating best practices were established resulting in a savings of $10mm / year.