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Photos 22-Nov
Case Study – Lean Manufacturing-Alfa Laval

Alfa Laval's business is divided into three divisions covering Energy, Food & Water, and Marine. Customers are found in various industries such as chemical, oil & gas, pulp and paper, wastewater treatment, marine, power and food to mention a few. Alfa Laval´s products are sold in approximately 100 countries, 50 of which have their own sales.

Sector: OEM

Engagement: 1 year

Workplace: 6 Facilities

Website: https://www.alfalaval.com

Objectives:

  • Improve productivity
  • Create workplace excellence and cultural change
  • Reduce Material handling
  • Improve quality

Problems:

  • Inadequate space for machines & other operations/layout
  • Improper material handling
  • Improper identification & labelling to machine accessories
  • More Time & effort Required For Transportation Of Shell
  • Scattered workplace
  • No Visual Management

Approach:

  1. Training, Coaching & Handholding of Operators, supervisors & managers
  2. Cross-functional action team
  3. Focused improvement workshop
  4. 5 'S' & Visual Management in the factory

Outcome:

  • 5 S Score improved from 11 % to 58 %
  • Space released by 25 %
  • Search time reduction by 85 %
  • Transportation time reduction by 40 % for shell handling & damages reduction
  • Productivity improvement by 20 %
  • Boost of Morale in the organization and cultural change
  • Material handling improved due to trolleys, pallets& racks implementation
  • Manpower optimization for shell handling by 50 %
  • Planning improved due to visual control Management

 

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