The Reftinskaya poultry farm increased development of employees by 2.5 times using lean production

2019: Implementation of lean production

On October 22, 2019 it became known what for half a year of participation in the national project "Labor Productivity and Support of Employment" of JSC Reftinskaya Poultry Farm almost by 2.5 times increased development of one operator on section of semi-finished products. At the same time the enterprise managed to balance working time of employees and to lower their daily loading. How without additional investments into production the efficiency was succeeded to raise the companies and to increase profit and why her top managers became adherents of the principles of lean production?

Without increase in quantity of the grown-up birds Reftinskaya is going to save flagman positions in the market due to increase in production of marginal products of deep processing. The share of carcasses of broilers in output should be reduced from 70 to 30%.

In May, 2019 the enterprise summed up the results of a pilot project on optimization of a flow of production and packaging of semi-finished products from the meat of broilers implemented together with experts of Federal competence center in the field of labor productivity (FTsK). The high load of the packaging line was one of the factors limiting production building. The investitsionnoyemky project on acquisition of the new equipment was even developed for the solution of this problem at the enterprise.

So, the mathematical calculations which are carried out by the CEO of poultry farm showed that real loading of the line does not make and 30%. Therefore, it was unprofitable to raise additional resources and to put them in updating of hardware when preserving the same technologies of management.

Having received such results, the management asked a question: where exactly resources are lost and how to increase labor productivity without essential investments? Experts of FTsK could answer this question.

As a pilot flow of poultry farm the flow on which made was selected and packed semi-finished products from meat of broilers: the share of this product in revenue made 19%.

First of all diagnostics of production processes was carried out, in particular, the card of a flow of value creation – the tool allowing to visualize a product production process is constructed.

The purpose of lean production is prevention of 7 types of losses: overproduction of products, obrazovyvayushchegosya owing to this excess quantity of stocks, irrational transportation, excessive movements, expectations during which the personnel stay in failure to act, excessive processing which is not required to the customer, and alterations of defects and defects. All listed losses involve increase in costs and decrease in profitability.

Mapping in the amount with the production analysis allowed to reveal that lines of cutting of raw materials during the day were loaded unevenly because of what there were peak loads on operators of lines. At the calculation of semi-finished products in a tray workers had to sort them repeatedly what about 2.5 working hours were spent for. Additional weighings also took away more than an hour a day. The lack, apparently, of an insignificant component – a container of reusable use – led to idle times on the line up to 20 minutes. Experts also found out that owing to irrational logistics the personnel should make up to 290 m of excess movements a day. Besides, up to 850 kg of a carcass it was not used because of defects when cutting. The defect of a packaging film caused idle times of the line up to 40 minutes a day because of what performance decreased almost by 60%. And because the personnel in a zone of the calculation were not timely informed on transition to other type of products, there was an overproduction of products up to 20 kg a day.

Having revealed the main losses, experts came to a conclusion that for performance improvement of the enterprise it is necessary to reduce equipment downtimes, to carry out rebalancing of operators on packaging lines, it is rational to organize jobs and to reduce the number of defects of raw materials which arrives on packaging.

Due to visualization of storage areas of raw materials and movement of bathroom scales from the main journey the route of the loader driver was reduced by 42 minutes a day. Line capacity was increased significantly by installation of the stop button and roller guides for laying of a carcass by a tray in the course of packing. Besides, the simple solution – change of the scheme of positioning of a carcass on a tray – allowed to increase more than twice development, earlier because of big time of a cycle performance decreased by 55%.

Moreover, at the enterprise the system of optimization and rationalization of a working space – 5C was implemented. She assumes creation of necessary conditions for execution of operations thanks to maintenance of an order and purity in the work area, disposals of unnecessary things and standardization of a workplace.

Following the concept of lean production, experts assumed to locate a packing material close with lines that allowed to reduce time of replacement of the lower film, to reduce relocations of operator and to save a working space from zagromozhdeniye. Training in tools 5C and working off of skills at practice there underwent more than 40 employees of the enterprise.

All complex of actions did not demand serious investments. As a result of implementation of a pilot project time of course of processes was reduced by 28.5% (from 31.9 to 22.8 o'clock), development of high-marginal products grew by 243%. Now 175 packagings of products instead of 72 as was earlier per hour are the share of one employee. The effect of optimization was felt on themselves also by employees: loading of operators on section during the day became more equal, the overlap of working shifts was reduced from 4 o'clock to 30 minutes, need for overtime work disappeared.

The solutions developed within a pilot project are already applied on other sections of workshop of processing. In plans of the enterprise – to optimize production of all types of high-marginal products^[1].

Notes