Sigma/Q1 is a leading manufacturer of quality packaging in Northland Central America serving various markets across the globe. The company’s primary goal was to improve plant performance and reduce operational costs.
The solution was to build a foundation for continuous improvement through OEE. The first step was to automate the data collection and analysis processes and introduce a real-time strategy. But the real key success factor was operator involvement in the performance improvement process. The company identified key contributors to reward them appropriately during performance reviews.
As a result, OEE increased by 40%, variability in run speed due to frequent starts and stops in the manufacturing process, was dramatically reduced and run speed was increased by 23%. Last but not least operators aspired to achieve higher levels of operational excellence, promoting a culture of continuous improvement across the various plants.
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