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Case Study:

Impruver System Implementation - Petfood Manufacturer

Author: Impruver
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Client Issue: Our client was a global leading petfood manufacturer who needed a means of tracking daily production performance in real time that engaged employees in business management. We needed to implement a system that was highly visual, required shop floor employee engagement, and established effective communication of plant issues and events.

Overall Approach: We implemented the IIoT Plan so that data could be collected, analyzed, and reported automatically from the production floor. The team opted to use their mobile devices to administer the software. We trained the teams on tools to drive down losses and address opportunities such as Root Cause Analysis and Kaizen. The system continues to automatically recognize success stories and coach individuals and teams to success.

Project Results: The client was set on a path of continued cost reduction which also fostered in a culture of continuous improvement. We saw marked engagement at the shop floor level and operators and mechanics began to lead improvement initiatives in their areas. OEE was driven from around 40% to nearly 80% in some areas with other areas beginning to follow suit.

Duration: 12 weeks

Keywords: continuous improvement, operational excellence, Impruver, lean manufacturing, lean six sigma, factory performance, performance improvement, employee engagement

Impruver System Implementation - Petfood Manufacturer Screenshot Views 7945
Industry Consumer Packaged Goods
Date Added January 14, 2015


Workstreams

Technology ImplementationMethodology: Partner with local IT to install sensorsResults: Completed in 3 weeks
Plant detail set-upMethodology: Worked with planners, supervisors, and IE to get production configuration set up in the system. Also trained teams on how to maintain set-upResults: Completed in 1.5 weeks
Trained teams on using the systemMethodology: Partnered with engineers and trainers on getting key personnel trained on getting the most value from the systemResults: 40 people trained in 2 weeks
Coached teams to initial resultsMethodology: Partnered with CI owners and operations leaders to coach the first teams to successful project completion. Afterward, first teams began to coach 2nd wave of project leadersResults: Drove 25% OEE improvement in targeted areas



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