Health & safety and productivity increase
- Client sector: Food processing
- Client sub sector: Pork meat processing
- Summary results of the Lean Ireland engagement: Slicer room yieled increased from 1,000kg to 1,500 Kg per head per week
Problem statement
The yield from a meat slicing department was lower that the target set by management, based on planned machine output and shift personnel capacity. In addition, the finished pack contained a higher than acceptable number of under weights and over weights, relative to the tolerance limits set.
Lean Ireland consulting/training work
"The Lean Ireland consultant spent a couple of days consulting with the operators on their issues, observing the performance of the busiest slicing line, and taking measurements of performance in key areas. The consultant observed a number of health and safety risks such as cramped space in the slicer area due to the presence of redundant equipment, variation in the temperature and size of the meat being sliced, poor access to essential tooling and an ergonomically unsound boxing area. The consultant facilitated a 5S two day workshop. The operator team took a dynamic and ruthless approach to the layout within the slicing department. All redundant equipment was removed, tooling areas were identified and maintained to a high standard, the chill temperature of the incoming meat was standardised, and the boxing area line was modified to allow easier access to both sides of the line. In addition a SMED workshop identified a number of further H&S risks that were eliminated, and several error proofing improvements were also made."
Detailed results of the client work
"(i) Yield on the line increased from 1,000 to 1,500 Kg per head per week. (ii) Operator morale soared and commitment to change increased, as they became empowered to run their own area. (iii) Key variables in the slicer set-up identified & standardised. The operators were ready and accepting of the implementation of OEE measurement on the line."
Consulting/training nature of engagement
The work with the client was a combination of formal workshops, support consulting and meetings and data analysis. Overall it amounted top 6 days of workshops, 8 days consulting on site and 2 days data analysis off site.