Cobra Plastics, a manufacturer of aerosol overcaps, has benefited from a number of process improvement initiatives over the past few years. These programs, which include lean manufacturing and a kaizen continuous improvement initiative, have helped the Macedonia, Ohio-based producer to boost its bottom line while sustaining operations through the economic downturn.
One of the lean manufacturing strategies involves a program called “Six S,” which stands for “sort, set in order, shine, standardize, sustain and safety.” Managers also implemented an employee development program, inventory replenishment efforts, accountability standards and a monthly kaizen manufacturing improvement event.
The kaizen event involves the participation of multiple groups across functional lines, Smart Business magazine reports. From these gatherings, members developed a “crash cart” system that helps supply the line workers with everything they need.
“Mold setters at Cobra no longer need to leave their station because they have everything they need nearby, neatly organized, and easy to monitor and maintain,” Smart Business reports. “As a result, the amount of time needed for a mold change has been reduced from as much as six hours to less than two hours.”