Savings of €8 million/year by applying Lean methodology to reduce the defect rate

Windscreen manufacturer given Silver Award by its multinational parent company for reducing its defect rate.

38% reduction in defect rate throughout the production line

78% reduction of the 'contamination' critical defect

86% reduction in intermediate stock (WIP)

€8M year total savings

NEEDS

IMPROVEMENT PROCESS

Assessing the current situation.
Creating a defects catalogue.
Self-control matrix and shutdown procedure at first defect.
Deploying the Kaizen approach for continuous improvement:
- Daily management cycle (SDCA).
- Weekly management cycle (PDCA).
Submitting results and conclusions to Management.

Related methodologies

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A robust approach for the standardisation, control and continuous improvement of the organisation's processes.

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Adjustment to demand using minimum resources and continuously eliminating waste.