RIBCON
Plastics plants producing caps, closures, containers, jars, jerricans, PET bottles, battery casings and other technical parts typically handle a wide SKU mix, frequent mould/colour/material changes and tight dimensional and aesthetic requirements. Common pain areas include long changeovers, high start-up scrap, leakage and defects, unstable weights, congested shopfloors filled with WIP, and chronic breakdowns that keep OEE low.
Separating internal/external activities, pre-staging moulds and change parts, standardising clamp heights, ejector lengths, water/air connections and task division to cut changeover time sharply.
Restoring basic conditions, cleaning with meaning, abnormality tagging, AM step 1/2/3 to stabilise machines, reduce repetitive breakdowns, bring OEE & minor stoppages under control.
Clear, visual SOPs and checklists for start-up, shut-down, parameter setting, trimming, joint-making and inspection, reinforced through skill matrices and TWI-style Job Instruction.
Moving from cluttered, zig-zag layouts to flow-oriented, well-marked workspaces with poi-ntof-use tooling, FIFO lanes, defined pallet stack heights and visual limits for regrind and WIP.
Using QC stories, Why-Why analysis, basic SPC/CP-CPK, PM analysis to stabilise critical dimensions with simple Poka-Yoke on fixtures, venting, clamping and handling to prevent cracks, leaks, short-shots, warpage etc.
Simple visual boards with key KPIs (OEE, scrap, rework, breakdown hours etc) reviewed in short huddles to drive daily problem solving and sustain improvements.
Changeover time reduction
OEE / operator productivity improvement
Material waste reduction
Raw material and finished goods inventory days reduction
We help streamline changeovers, layouts and material flow so operators spend more time moulding and less time searching, walking and waiting. SMED and standard work cut mould and colour change times, while 5S, visual controls and TPM reduce leaks, breakdowns and scrap driving higher uptime and more reliable deliveries.
We focus on improving process capability, quality at source and robust maintenance. Using QC-story, Why–Why and PM analysis, teams attack recurring dimensional and leak issues and standardise correct methods. With TWI-based skill building and daily management, plants cut rejections and rework while increasing confidence in every shipment.
We help standardise recipes and set-up, simplify mould changes and build strong operator routines for start-up and quality checks. By organising mould stores, tools and spares and embedding visual standards, plants are able to cut start-up scrap and reduce changeover time leading to improved OEE.
Afroplastics, Kenya
Besmak Components, India
Blowplast, Kenya
Garware, India
JJ Plast alloys, India
Precision Plastics, Kenya
Sintex Plastics, India
Lean Kaizen turns cluttered, breakdown-prone moulding shops into stable, high-velocity operations with fewer defects, faster changeovers and operators who know exactly how to run to standard, every shift.
With experience across diverse industries and challenges, we deliver unparalleled insights and solutions especially designed as per the needs. For more details, contact us today!