Because of the previous time- and labor-intensive disposal solution – during a ‘Gemba Project‘(a project where employees restructure their workplace regarding lean-management) they got the idea of saving at this point ‘disposal‘ time and labor expenses.
Material to be disposed of
The raw material which is needed for producing chocolate is delivered on pallets. Milk powder comes packed in paper sacks and hazelnuts in film sacks. For example, bubble wrap is used to protect the nuts against damage. Cardboard-sheets and stretch films are further packaging material. The amount of material is 270t per year which is divided into 132t cardboard, 43t film, and 96t paper sacks.
In the production, each three roll containers were distributed at several places. The staff always brought the occurring material to these places. In each shift, the forklift driver collected the filled roll containers and brought them (in all weathers) outside. Afterward, a tilting device was set on the forklift and the roll containers were dumped into the waste compactors for paper, film and residual waste. The dirty roll containers needed to be cleaned before brought back in the production. This procedure took per shift and collection of about 2 and 3 hours.
- Time- & cost-intensive disposal
- Long transportation routes
The first approach was to reduce walking routes of the employees and thereby labor input and labor time. From the beginning order and cleanliness were important. As soon as the employees had less time for the disposal the collecting containers were filled up very fast in the previous solution. In total eleven balers are placed inside the factory, regardless of weather conditions. The balers create order and cleanliness and the employees are very satisfied with the handling.
Savings of 92% manpower
The balers are placed in a way that staff reaches the place of installation by the shortest route. The material gets collected in these balers. Now every second or third day one bale is being picked, before the forklift driver had to collect the material time- and cost-intensive three times a day for two hours. The forklift driver got new tasks because the balers facilitate his work and the disposal is less time-intensive.
Finally, the bales are moved from the baler to the dock and then comfortably placed in a trough. The tip at the forklift that was used for the previous roll containers is not needed anymore and the time for switching is saved. Due to the compact bales, more material fits into the trough. So the number of transports is reduced and only one parking position is needed for the container in comparison with the former disposal solution which needed two.
The opinion of the customer
Mr. Kamphowe, Plant Manager says: ‘Suddenly having revenues by marketing the bales was an eyeopener for us. Now we sell our bales. Due to these revenues, the project became that interesting that we adapted the balers in the testing department to the whole factory. Now eleven balers are placed on different floors in the Herford factory. The Strautmann salesman advised us very well and took us to reference customers. He told us about the right size of machinery and the differences in the compaction of cardboard and film. Moreover, he calculated all the costs and revenues of the project. This was plausible that we immediately presented it to our management and got immediately the ‘go!‘. The project was conclusive and the figures matched. It became a huge showcase at Weinrich and also at ‘Gemba‘. The disposal solution with balers is a new thing and one of the most successful projects – a highlight.‘
- Component consultation
- Short payback period of only 1,8 years
- Order and cleanliness in the factory
- Optimized internal logistics
- Less time and manpower
- Reduction of disposal costs
- Revenues for bales
- Economic bales
- Satisfied employees
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