The effectiveness of Lean application at Binh Duc Packaging Factory

Binh Duc Packaging Enterprise, belonging to Loc Troi Group Joint Stock Company, specializes in manufacturing and trading in carton packaging, PP packaging for consumption in the domestic market. The enterprise has been operating for more than 20 years and the total number of employees of the factory is now 300 labors. Joining the Government’s lean application support program, the Enterprise was guided by Quatest 3’s consultants.

Assessing the current state of the factory before applying lean, the consultants found that:

– The factory’s productivity is low, not meeting the expectations of the enterprise leaders;

– The shortage or excess of production often occurs due to the lack of coordination between the stages, especially the lack of coordination between the production department and the sales department;

– Some stages in the production process are not value-added and unnecessary, such as cleaning blankets while changing the gauge;

– The norms of raw materials are not yet standard, leading to the advance or excessive preparation of raw materials;

– The arrangement of personnel is still in many unreasonable places, the personnel skills are not high;

– The rate of rejects is still high above 3%.

– The production area is not tidy at the moment, the objects have not been arranged and arranged scientifically, thereby leading to waste of time for workers to search for items when needed.

To solve the above problems, the Enterprise improvement team together with consultants has given the following groups of solutions:

– Changing production planning method: coordinated production and business to reduce the number of packaging changes from 10 times / day to 8 times / day. This helps to limit waste generation;

– Set norms to control more closely the advance of raw materials to limit waste;

– Improving automatic folding conveyor to reduce the number of workers, thereby contributing to increase productivity while ensuring product quality;

– Equipped with automatic counting device to ensure accurate quantity counting and eliminate substandard products. Accurate counting results help sales and production departments adjust plans in a timely manner;

– Training for Managers and Team leaders how to manage and arrange work properly. Workers directly working on the machine are trained in job manipulation to help improve their skills;

– Apply 5S and intuitive management so that the workshop is neatly arranged, scientifically, reducing the time of searching and waiting for employees.

After the above solutions were put into use, the Enterprise has obtained very positive results:

This result is thanks to the drastic direction from the Board of Directors of the Enterprise, the enthusiastic participation of all departments as well as the close coordination of consultants. This is a boost for the Enterprise’s lean activities to be maintained and further developed in the coming time.

Productivity and Quality Office