Major Dairy Realizes $509,000 in Savings from Uniloy Blowmold Kaizen
Client is currently purchasing 40% of half gal and gal jugs from outside blowmolders due to equipment reliability issues in 3 blowmolds. The weekly cost variants ranged from 20,000 to 25,000. The total cost savings opportunity to eliminate outside purchases was 509,000.
Data collection on the blowmolds was inconsistent and no reliable information was available to manage performance.
The 3 blowmolds undersupply the filler by 873 jugs per hour at the OEE rate of 82%
The half gal blowmold has one head that is not operational due to mold reliability issues which equals a 12.5% OEE loss.
Operators begin collecting data on the blowmold in the following areas:
No of bottles produced per day/ hour
Delay times and types
Pounds of scrap and regrind
Identified top 3 downtime reasons
Cooling bed lubrication
Dirty and cracked molds
Lack of operator trouble-shooting skills, including incorrect weight adjustments and Parison adjustments.
uniloy blowmold success story
Wrote detailed trouble-shooting guide.
Wrote detailed lubrication procedure.
Implemented Standard Work for Leaders Board.
Implemented visual management.
Posted one point lessons for lubrication and adjustments.
Built shadow boards for tools and cleaning supplies.
Wrote standard work for operators and posted it on boards.
Implemented visual workplace for lubrication points, weight adjustments, and mold and mandrel cleaning.
Trained all three shifts of operators and mechanics in all tools and procedures.