Recharging the battery plant
In 2002, the AKOM plant was launched in Tolyatti, where batteries for motor vehicles were manufactured. The enterprise was able to reach its design capacity of 1 million batteries per year by 2005. At present, this production covers approximately half of all market needs within the country, and also accounts for 64% of battery exports. For a large-scale modernization of the enterprise, during which it is planned to double the production capacity, specialists from the Federal Center for Control were invited.
As a pilot project, experts modernized the section where battery plates are manufactured. This division provides 66% of financial receipts, which in 2017 amounted to 4.6 billion rubles. In the process of performing the work, the warehouse stocks of plates and their nomenclature were reduced, the routes for moving blanks were reworked, and the number of defective products was reduced. The locations of the operators in the section were also optimized.
Example of lean manufacturing implementation at a plant
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As a result, the installation of only one teacher data package weighing complex at the operator's workplace resulted in a travel saving of 1.6 km and 21 minutes of working time. According to Oleg Beltsov, Director of Production Capacity Development at AKOM Group, the production process time was reduced by approximately 30-35%.
The changes made allowed to increase the employee's production rate by 8%. Labor productivity at the enterprise for the reporting year increased to 10.5 million rubles, an increase of 19%. Based on the positive result, in the near future it is planned to optimize another section for the production of finished batteries, and in the future the lean manufacturing system will be implemented in the office processes of the organization.
Extracurricular activities
Lean manufacturing is applicable in almost all industries. This statement is supported by the optimization of the work of school No. 1474 in Moscow. The educational institution is implementing the project "Comfortable School", within the framework of which the management decided to speed up operations that are not involved in the educational process. One of the six buildings was chosen as a pilot project. As a result of surveys conducted by experts, it was revealed that the students are most dissatisfied with the queues in the locker room, cafeteria and library.
An example of lean manufacturing implementation in a school
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The cloakroom operation was resolved as follows: an additional section was opened, cabinets with shoe compartments were installed, signs with class numbers were installed, and the operating mode was changed so that the changing rooms were open 5 minutes before the last bell. The problems in the canteen operation were resolved by combining the serving line with the buffet, and by setting up separate entrances and exits to the room. Additional seats and a system appeared that signals when trays are running low.
The library has become more modern, which is reflected in the creation of media and video zones, and the ability to order books remotely using smartphones or tablets. Search and accounting for them can be done using a barcode scanner.
All these actions led to an increase in library attendance by 50%. Olga Vasilyeva, head of the Ministry of Education, stated that the Comfortable School project can be implemented in every educational institution.
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