Unionaire has a dire need to an Effective Supply Chain, with 6 plants of different products from heaters, air-conditions, cookers and stoves etc… one of the challenges lean deployment team faced with the inaccurate demand forecast. Unionaire team made significant efforts to implement Oracle ERP system and review master data for all entries, which is now fully implemented and functioning in warehousing and still underway in purchasing and finance.
Exports needs over the last 5 months was near to forecasting to a great extent that exports were 100% of the production during this period. Having said that, domestic forecast is more difficult.
Unionaire has made extensive work with Oracle and continues efforts to fully complete utilization of ERP in finance and purchasing as well as supplier management.
Quick Change Over: In plastic plant a problem remains unsolved which negatively affected the quick change over, new machines will be moved to implement 5S and allocate a space next to it with the material needed for 2 days.
2 challenges the changeover team faced that each new machine will be allocated a certain space with its allocated materials
A dedicated supervisor to monitor 5 S on a daily basis, supervisors were challenged with the frequent changing production orders. On average they make 36 change /day. Lean is quite beneficial handling such change and gain agility and flexibility curbing them.
Quick Wins…
- Stock items, print outs with item code /no and description are printed and posted on each item available.
- Unification of description through CRM and weekly production is posted vs planned weekly production planning. Accuracy of Demand Planning reached 75% to date.
- Significant decrease in days of Absence among plant labors during deployment of lean indicates higher engagement and motivation trends.
- Middle warehousing: providing material for 2 day production to cope with changing production plans and meeting urgent requests.
- 5 S implemented successfully and operators are being trained to reduce the WASTE.
- Air-condition plant have become agile to change in production planning and stove plant is going through the transformation into Lean to become agile too and flexible to productivity plan change.
