Reduction in cutting machines’ rejection rate in printing

Problem solved : 25% reduction in the rate of paper cutting rejects (industrial paper mill) - reduction in series start-up time / campaign (SMED + AMDEC)

Client :

Paper mill : manufacture and marketing of Papers for printing - writing - 90 people, turnover : 20 M€

Methods used :

courbe de maitrise du taux de gâche papier après conseils
paper waste rate control curve, after consultancy

 SMED (method for reducing start-up times and defects) SMED : Single Minute Exchange of Die
To film a start-up and to study the details and the wasted time and inactions of the helpers, allowed to balance the tasks between the staff and to save time and raw material : the machine running permanently fast with raw material during this phase.

 FMECA of production defects FMECA : Failure Mode, Effects and Criticality Analysis
This analysis with the operators allowed the identification of technical modifications on the machines and to prioritize and quantify the impacts before each request.

The modifications were proposed, then requested from the machine manufacturer and installed : this was the longest part of the project. Waiting for these modifications generated hope in the team and showed that the management was ready to invest in elements whose ROI (Return on Investment) was studied and very fast.

 Méthode de management quotidien de la performance - Formation - action
An absence of management by objectives was detected in this workshop because of the lack of understanding of the business by the manager who also supervised other workshops known by him.

The presence of a method showed him that one can also manage a workshop with unknown technique by a simple and effective methodology.

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