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News Release from: PICME | Subject: Conference June 8
Edited by the Processingtalk Editorial
Team on 11 May 2004
Geberit Terrain to speak at PICME
moulders event
Leading European plumbing and drainage supplier Geberit Terrain is currently rounding off a course of masterclass improvements with PICME, and will share some of its new production expertise on June 8
Leading European plumbing and drainage supplier Geberit Terrain is currently rounding off a course of masterclass improvements with PICME Geberit Terrain will share some of its new production expertise at a special PICME/BPF seminar for plastics processors on June 8, 2004
This article was originally published on Processingtalk on 9 Mar 2004 at 8.00am (UK)
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The event will be held at leading automotive moulder and Plastics Industry Award (PIA) winner, Eaton Automotive in the West Midlands.
Van Williams, Geberit Terrain Operations Director will lead the company presentations on June 8.
He says that 'we really took to the PICME problem-solving philosophy of "inch wide, mile deep".
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Akzo Nobel has been working with PICME on manufacturing improvement techniques that have led to a significant increase in plant availability and a decrease in plant downtime at their Hull site
Drilling down into the fundamentals can be a bit testing - but little by little, we went further down a funnel of factual analysis, eliminating our pet theories until the true answers were revealed'.
These answers were generated by Geberit Terrain's dedicated eight-man, cross functional team, with more than 123 years experience between them.
Within three months the Geberit Terrain team had identified the needed solutions; had freed new capacity - thus saving the cost of a new extrusion machine - and had halved the potential for waste.
From the outset the Geberit masterclass team set themselves high standards: They resolved to tackle the most under-performing extrusion line on the shop-floor, where 91 general improvement actions were identified for execution.
In similar manner, 28 actions were set for tooling and calibration issues, 24 actions for materials issues, together with a host of other points around the production line.
Van Williams explains that the line in question had been inexplicably under performing.
'It was tying up our staff across all four shifts to try and put it right; it was reducing the machine's potential availability and was also producing too much waste.
Most involved had a pet theory as to the cause'.
The more rational of these theories included machine conditions and also a suspicion about the existing materials formulation.
The suspicion about the formulation was immediately removed when trials with alternative materials were run and produced no adverse side effects.
It was then established that only one colour was at fault, and from there, it was established that the problem could be traced to the particular additives during processing.
As a consequence new additives are now being trialled, and are expected to come onstream shortly, delivering even better product quality.
The Geberit Terrain enthusiasm for manufacturing improvement - and the recent return of the company to profitability - can be traced to the tenure of Chris Bayliss as managing director.
Now in his fourth year at the helm of the GBP39 million turnover site, Bayliss believes passionately in two things: customer focus - and making the most of our people.
We spent GBP100,000 on training last year.
It's what it takes - and it's worth it.
Guys that were sitting on the fence have now got confidence.
Their confidence gives me confidence.
Customers are taking notice.
Since the beginning of this work, we are now conducting regular customer visits; they get the opportunity to see the product manufactured, undertake a site tour and get to talk to our people.
They like what they see.
' However, Chris cautions, manufacturing management in general to have patience with the process: 'Sustainability is key.
'"Big bang" solutions merely create islands of excellence which eventually drop back to the general standard.
Ultimately we require something akin to 'a way of life' in manufacturing to be created here.
It needs to be self sustaining and without a need for "policing"'.
Chris Bayliss adds that 'at Geberit, we're fortunate to have a parent company that really understands these issues in the context of effective medium to long term planning and vision.
That attitude has helped the group to achieve continuous growth in its 100 year history and to deliver well above average return-on-sales in recent times.
As part of out shorter term focus at Geberit Terrain, I am now tasking PICME and our company team to reduce the total waste bill by 50%.
It's a tall order but I believe we can do it.
We have certainly made an effective start.'.
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