LEAN GO UP realized the following projects (amongst others) :
- Start-up of a new carseat foam production plant according to the Lean Manufacturing principles
- Start-up of a new cutting, sewing and assembly plant according to the Lean Manufacturing principles
- Installation of component conveyor which runs synchronously with foam conveyor in order to eliminate walking of operators to get the components and preventing that the wrong type of insert is put in the foaming mould (Poka Yoke)
- Change of bolts & screws to quick release couplings on water and pressurized air hoses of foaming moulds to speed up toolchange (SMED)
- Hanging sets of keys & wrenches in the mixing head area on a shadowboard to facilitate & speed up change of mixing head (SMED)
- Instalacja : podczas gdy odbywa się mycie pierwszej formy, druga jednostka grzewcza zagrzewa drugą formę spieniającą (przygotowanie do mycia), co redukuje czas oczekiwania formy na mycie ("SMED")
- Installation of 2nd heating unit to preheat a foaming mould (needed for cleaning) while the foaming mould on the 1st heating unit is being cleaned (SMED)
- Installation of mobile turnable platforms on which packaging containers are standing (to be filled with ready parts) to eliminate turning of fork lift by 90 degrees to pick up a full container (Floor space reduction)
- Line balancing in sewing and assembly production cells with bottleneck elimination to facilitate one-piece flow (Pull & continuous flow)
- Installing Kanban as production scheduling method in metal, plastic injection, foaming and assembly production units (Kanban)
- Productivity increase by reducing injection time and raw material usage reduction by lowering part weights in plastics production (Reduced capital need)
- Connection of sewing line with foaming line according the pull principle to eliminate work-in-process (Inventory reduction)
- Use of green/red coloured pressure gages and temperature gages for easy & quickly checking (TPM, 5S, Visual Management
