CIBA Speciality Chemicals

The Company

CIBA Speciality Chemicals based in Paisley manufactures a range of pigments used to colour various types of products.

The challenge/issues

CIBA was going Lean globally and CIBA Paisley needed to get started on the journey, ideally with the help of a local consultancy. It needed to realise the many benefits of Lean across the entire operation to reduce costs and improve service levels. The area chosen for initial attention was their RMUP Line 200 which was required to run 24/7 to meet demand. They needed to find a way to introduce an additional product into this line.

How Ross International helped

We worked with David McKellar the (then) Manufacturing Operations Manager to plan and execute a Kaizen Blitz on the Line 200. We identified the scope, goals and the team required and set about preparing for the Kaizen Blitz week. Pre-meetings were held with the Kaizen Team and with all operators and others likely to be affected by the new processes, to invite their co-operation and assistance.

The Kaizen Blitz week followed the usual Ross International pattern with training on Day-1, establishing the current state on Day-2, designing and developing the new ways on Day-3, testing and getting feedback and continuously improving on Day-4 and finished with pulling together and action plan and making a presentation on Day-5.

Follow-through visits took place to ensure the action plan was being worked and that any obstacles to progress were being elevated for attention as required.

Results

Throughput increased by 80%.

5S workplace organisation score increased by 800%

Batch standard quality showing 100%

80% improvement in drying cycle eliminating a 3 hour delay.

40% reduction in quality testing time.

50% increase in packing productivity.

Outcomes

Annualise electricity saving of £125K due to better, faster drying process.

New products fitted in to the Line 200, Cleaner, safer working environment.

Batch quality levels significantly improved reducing rework and scrap.