Dong Nai Plastic implements productivity improvement tools

Dong Nai Plastic Joint Stock Company is one of the major companies selected to apply LEAN under the Government’s support program. Dong Nai Plastic is a leading company specializing in the production of plastic pipes and fittings used in water supply and drainage, and export packaging.

Although it is a large enterprise with more than 20 years of establishment and development, there are still some shortcomings in the production process of the Company:

– Most of the tools, tools, materials and materials in the parts are quite messy, not arranged in order; workshops, warehouses; The exterior does not ensure clean hygiene.

– The stage of packing finished plastic beads, transporting pallets to the warehouse shelves and transporting to the production area is time consuming and labor intensive.

– The machine still has phenomenon of stopping and waiting, the efficiency of the machine is not high.

Under the guidance of experts from QUATEST 3, the company has implemented the following solutions:

Implementing 5S at accessories factory:

Creating a tidy work space, more convenient for workers to work on and contributing to improving the company’s image to customers; The company has established regulations and criteria to evaluate and maintain 5S activities after the project ends; Raise awareness about the benefits of 5S to work performance and product quality.

Improvements to reduce shipping and redundancy

Designing and processing material tanks with a large capacity located in the center of the production area; Fabrication of automatic material transmission equipment from the granulator to the central tank. Thus, it can reduce 1 hard labor (bagging and palletizing finished plastic beads); reducing 2 stages of forklift transport (reducing 1,380 m for forklift transportation); And help increase output 24h by 1.5%.

Reduce time loss in production

Shorten mold replacement time by performing well preparation (personnel, equipment, tools, …); issue the operation instruction sheet, work order and implementation monitoring combination; Training in knowledge about molds, machine functions and how to fix common failures; Arranging production so that the replacement molds have similar raw materials, hydraulic ben, machining mode (material change limitation); Combining material change and drying while changing molds; Installation of auxiliary equipment, jigs to support the job of changing molds. Result: Time lost reduced from 1,805 minutes to 705 minutes; Duration increased from 83.3% to 92.6%.

With the above positive changes, the Board of Directors has decided to expand the application scope of Lean tools to other areas of the factory in Dong Nai.

Productivity and Quality Office