Lean Manufacturing System

Why P4P starts with Lean ?

Because we are looking to sell to our customer, not only packaging, but mainly we are looking to improve Customers’ profitability and Working Capital.

• SQCD (Safety, Quality, Cost, Delivery)
• Guarantee Customer Satisfaction
• Increase Sales and Profits
• Insure Long-term Health of Company
• Create Sustainable Competitive Advantage

Principles of Lean thinking

VALUE – what customers are willing to pay for

 VALUE STREAM – the steps that deliver value

 FLOW – organizing the Value Stream to be continuous

 PULL – responding to downstream customer demand

 PERFECTION – relentless continuous improvement (culture)

Lean is

“A systematic approach to identifying and eliminating waste (non-value added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection.”

 How P4P is able to start a complete Lean Manufacturing System (PULL SYSTEM) in packaging industry (PUSH SYSTEM) ?

Following

• more than 10 years in Automotive Industry whith delivery cutomers like Totoya (UK : Birmingham), Ford ( Germany : Köln and Saarlouis), Renault (France)
• learning Lean Manufacturing System (stay in Toyota Japan, in Toyota UK, in Ford (Gemany)
• A Team with significant experience in Packaging (folding cartons).

We define the P4P Production System = 100 % Lean Manufacturing System

It means :

• A lay out without waste (MUDA) => only adding value ( = What the Client should pay) => You have to see it in Fleurus Plant (Belgium)…
• Equipments choosen in line with the Lean Manufacturing System (Takt Time, pull system), digital, quick change over , capacity used
• People and machine separation
• SMED => change over is one of our success
• 5 S ( Sort, Arrange, Shine, Standardize, Sustain)
• Visual Management ( Production Control)
• KAIZEN (Continuous Improvment)
• Quality Management (problem follow up sheet).
• Lead Time => never defined on week but days.
• Complete on Time Delivery Measurement (target Customer)
• …

Please take contact to visit us,  You will be impressed

Lean Goals

• Zero defects
• 100% value-add
• Lot size of one
• Pull of the Customer

Lean Manufacturing System

Just-in-Time : it means

• Pull Systems/Kanban
• Point Of Use Storage
• Quick Changeover/Setup Reduction
• Continuous Flow
• Takt Time

Jidoka : it means

• Quality at the Source
• Poka Yoke
• Andons
• Effective Problem Solving

Standardization : it means

• Standardized Work
• Heijunka/Leveling
• Supermarket
• Kaizen

Lean manufacturing model
P4P Production System

Typical Results from Lean Conversions

Toyota’s Philosophy

• Customer first
• People are the most valuable resource
• Kaizen (continuous improvement)
• Shop floor focus

Lean = Eliminating the waste

Typically 95% of Total Lead Time is Non-Value Added !!!