Improve production efficiency through applying Lean at Binh B.F.C Co., Ltd.

Binh B.F.C Co., Ltd. is an enterprise specializing in the production and processing of forest products, wood with the main product of outdoor furniture for export. The problem that makes the Company a headache is to find a solution to stop the slow delivery. Participating in the application of Lean government supported by the Government, B.F.C has coordinated with the consultants from QUATEST 3 to solve this problem.

After conducting the analysis, some reasons leading to the delay of the production progress were pointed out by the research team as follows:

1. Most of tools, supplies, materials in many parts of the factory are messy, not in an orderly manner. There are many unnecessary equipment and objects that do not serve the production work occupying the factory area.
2. At the cooling stage: For 818 tabletop products, the average productivity is only 1 table top / person / day. The stage has 10 workers, it needs to process orders with the number of 518 tables and need to be delivered in 30 days. Thus, the productivity has not met the requirements of the order.
3. The work of transporting raw materials from the aluminum warehouse to the aluminum factory is quite far away. On the other hand, the current wood painting line has not yet met the requirements to produce complex items with high requirements, needs clean paint rooms and indoor premises, so it is necessary to re-arrange the ground to reduce transportation costs at the same time. to meet the production requirements of complex items.

To overcome the above reasons, the expert advised the company to apply LEAN tools, specifically as follows:

Apply 5S tools

5S tool has been applied by the Board of Directors of the Company in all areas of the factory. The company performs positioning of machinery and equipment; At Material Warehouse, locate materials for easier retrieval; Making a chart of each shelf makes it easy to find supplies; Assigning 5S responsibilities to each individual.

Improve cold process productivity

To improve the productivity of the process, the company uses conveyors to form a production line. Breaking down the stage into many different jobs; Standardization of vehicles for materials.

After implementing the innovative solutions, the stage productivity has increased to 3 tables / person / day (an increase of 300%). Within 18 days, the order of 518 tables was processed. If converted to money, the company has reduced costs by nearly 76 million / month. The important thing is that the solution has helped to satisfy customer requirements, create prestige, reliability, increase brand name, increase number of custom orders, etc.

Layout of production site

Rearranging the production site helps shorten the distance to move materials from aluminum warehouses to aluminum factories, from 93.5 meters to 71 meters; After arranging materials, materials, furniture according to the new layout, the company has saved the area of ​​the aluminum workshop from 1,500 m2 to 1,300 m2; The transportation distance from the newly painted wood to the assembly area is reduced by 10 m.

Thus, the application of LEAN in the production process has clearly brought efficiency to the company. The Board of Directors of Binh B.F.C decided to continue to expand LEAN’s staff, training LEAN knowledge for other personnel in the coming time. Every 3 months, the company will hold meetings to review LEAN activities to review the results achieved, and provide bonuses and recognition of employees’ contributions to the activity. improve productivity and quality.

Productivity and Quality Office