| Client: Specialty Printing Firm with Fortune 100 Clients |
Client Success Stories
Charles Brooks Associates, Inc
| BACKGROUND: Plant had recently undergone a six million dollar expansion which included new state-of-the-art printing equipment. Expansion of the workforce and increased business volume led to under-trained and inexperienced operators running expensive equipment at less than profitable rates. Changeover times were excessively high. Low unemployment in the area made it difficult to hire and retain qualified employees. In-house training and engineering experience was lacking. ACTIONS: The initial CBA survey indicated an opportunity for a 25% plus reduction of press Changeover time compared to "quoted" time. Project Coordinators and CBA developed a comprehensive Changeover process in preparation for training on a "pilot" press. Procedures for Changeover were developed and educational sessions held with the more experienced operators. Inexperienced personnel were trained to perform specific roles during the Changeover process and results were measured. Adjustments to the process were made using the knowledge of all department supervisors and hourly personnel. Specific operations training was developed and implemented for all job classifications. Training included equipment operation and troubleshooting techniques. The process was "rolled-out" to other department presses. RESULTS: Press Changeover times decreased by 35% during fourth month of program. Start-up waste and scrap reduced by 50%. Running efficiency improved by 10% Die damage significantly reduced. Pre-make-ready techniques improved first time through quality and efficiency. New methods of press registration were developed. Safety and environmental standards conformance were improved. |
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