Introduction: We worked with Ital Beauty Nippers – A leading Global Beauty products manufacturer. Productivity, Quality Improvement, SMED and 5S Implementation were deliverables for our engagement.

Our Activities: We have implemented the Continuous Flow and Lean Manufacturing System in the Production line. Initiated the Root Cause Analysis and Quality Problem Solving for the Quality issues. The Gamification technique is used for the 5S Implementation. Once 3S is initiated, we have implemented the SMED technique to reduce the Change-over time.

Results: 39.5% Improvement in the Overall Productivity is achieved in the Lean implementation. The Changeover time is reduced by 50%. The Quality rework is reduced from 19% to 5.1% and the quality rejection has reduced from 4.4% to 0.6%. 5S has also contributed for the productivity improvement.