PROBLEM

• This family owned meat processing company Has been smoking various meats since 1936 with continued success. Recently, competitive pressure has squeezed market share and profits.  The executive team recognized a tremendous need to improve operational performance with the implementation of a total Lean six Sigma Enterprise.
• Defect wastE and customer complaints have increased by 30% in the last 6 months increasing cost of processing and negatively affecting profitability.

APPROACH

A Quality Assessment and Shingo Prize Assessment was  performed in collaboration with the executives and the plant leadership team.  This included current and future requirements and a review of all available manufacturing and quality data (throughputs, scrap rate, rework, complaints, etc.). the implementation roadmap was developed based on the business needs and opportunities for improvement.

SOLUTION

Statistical Process Control (SPC) and Lean Six Sigma (Standard Work and Standard Recipes, Synchronized Flow and Balanced Work, visual workplace, Quality Standards) were launched in a phased approach to allow for the needed focus on individual lines during the initial launch (90-120 days).  AM Teams are identified for each line.  Teams include Operators from each shift, a mechanic, an Operational Leader and a Sumbexpert.  AM was launched on each line using t he three-step approach:

1. Initial Cleaning
2. Countermeasures
3. Standards