Manufacturer of Thermoplastic Piping Systems

OPTIMIZING RESOURCES ACROSS THE ENTIRE OPERATION

COUNTRY: Canada (A total of 6 Projects have been completed to-date across Canada )

PRIORITY OBJECTIVES:

To improve their overall work processes and to subsequently improve the output on each of their extruder pipe lines. The support departments (Blending, Maintenance, Setup/Changeover) also targeted improvements to their processes and levels of non-effective time.

PVA’S RESPONSE:

 

To implement a Management Operating System in all departments that would better plan for and optimize all required resources. The Supervisors and Managers also received appropriate training and coaching to allow for improved management of their processes. In particular, the project developed and implemented the following:

• expectations, objectives and key volume indicators
• improved planning, follow-up and reporting system tools
• clear roles and responsibilities for Managers and Supervisors
• a Problem Resolution Mechanism that focused on operational issues

PROJECT RESULTS:

As a result our Client achieved:

• improvements in kg per man-hour
• improvements in both unscheduled downtime and rejects
• improvements in kg blended

In addition, standards were developed for all lines and a planning tool was implemented that allowed each line to be planned for all activities required to produce a pipe from set up to quality checks.

PERPETUATION OF RESULTS:

Perpetuation is being supported through the on-going partnership between PVA and this company. There are employees in each of the Plants that were trained as Continuous Improvement Coordinators to conduct regular system audits. PVA also conducted audits in order to ensure site-wide management system compliance and a successful installation of their Continuous Improvement Program.

CLIENT TESTIMONIAL:

“The greatest benefit for IPEX was the implementation of a solid Management Operating System in all 6 Plants. Our Plant staff – from Shift Supervisor to Plant Manager – became stronger Managers, and because of that, started to deliver better results. It is by far the best training exercise that we ever gave our Supervisors. This is achieved because, contrary to a lot of other types of training, it is not just a 2 or 3 day theoretical program, but a 26 week program that covers both the theory and practice of solid management techniques. I would strongly recommend PVA to any organization.”

- Frank Yorio, Senior Vice President Operations



For more results that we have achieved within the Injection and Blow Molding Industry