Introduction
At Marel Slovakia, we have realized that the key to maintaining competitiveness and achieving long-term success is the implementation of robust principles of quality, efficiency, and productivity. These three aspects are the fundamental pillars of our corporate culture, influencing every aspect of our production. To translate these principles into our day-to-day operations and processes, we decided to partner with FBE, a leader in process improvement and training.
Challenge
Although we had the basic principles of manufacturing in place, we found that our employees needed a deeper understanding and practical skills that would enable them to effectively apply these principles in practice. Our priority was to improve production quality, increase productivity, and optimize efficiency while reducing costs associated with poor quality products and excess inventory. We therefore decided to train with FBE experts to achieve these goals.
Solution
FBE took a comprehensive approach to our needs, providing us with customized training that included the basics of standardization, visualization, Poka-Yoke, basic FMEA, PDCA quality improvement cycle – Kaizen, 5S, pull principle (“pull by the customer”), 9 types of waste, and other important tools and techniques. The training was conducted in the form of practical simulations of the production process, which allowed our employees to immediately apply the learned principles and observe their impact in real-time.
First Simulation: Elimination of Poor Quality
The first simulation focused on identifying and addressing the causes of poor quality in manufacturing. Employees analyzed the issues that led to defective products and discussed ways to eliminate them. The results of this simulation provided deep insight into how quality affects efficiency and productivity, and consequently our company’s bottom line.
Simulation Two: Implementing Quality Solutions
Based on the findings from the first simulation, our staff applied the suggested improvements in the second round of the simulation. As a result, we were able to significantly reduce the level of poor quality, which had a positive impact on the remaining production indicators. This progress confirmed the importance of continuous improvement and clearly demonstrated how quality directly affects efficiency and productivity.
Simulation 3: Efficiency and Productivity at Work
In the third simulation, we focused on the principles of efficiency and productivity. Our employees learned how to properly apply these concepts and how their use changes the production process. The results of this simulation once again confirmed that the correct implementation of theoretical knowledge can significantly improve a company’s bottom line.
Results
During the training, we saw significant improvements in all key areas. Our employees understood the differences between quality, efficiency, and productivity, and learned how to apply these concepts correctly in their work. Simulations of the production process allowed us to gain hands-on experience and immediately see the results of our efforts.
The best teams in the simulations achieved significant improvements in quality and efficiency, which were also reflected in their resulting economic indicators. Based on these successes, we have decided to continue implementing these principles in other areas of our production and to implement these practices in the training of new employees as well.
Conclusion
The cooperation with FBE has brought Marel Slovakia concrete and measurable improvements in production. The implementation of world-recognized principles of quality, efficiency, and productivity into our corporate culture has enabled us to reduce costs, increase profitability, and improve the overall performance of our production processes. We will continue to utilize and disseminate this experience to our employees to ensure the continued growth and success of our company.
