Lean production technologies are introduced at all Ventall plant enterprises

2021: Implementation of lean production technology

Lean production technologies will be introduced at all enterprises of the VENTALL plant. This became known on July 6, 2021.

In August 2020, VENTALL became a member of the national project "Labor Productivity," initiated at the federal level by Russian President Vladimir Putin. But due to the epidemiological situation, the introduction of lean production tools was postponed to the beginning of 2021. And already in the first quarter, such good results were obtained on the pilot stream that best practices are planned to replicate to other production processes.

We are implementing the national project together with the RCC, the Business Development Agency, which provide invaluable assistance in identifying and solving the main problems. The representative of the agency, Ivan Golikov, is in constant contact with our working group, consisting of heads of departments, "says Alexei Shataev, master of the procurement workshop, head of the working group of the Lean Production project.

As a pilot site for testing lean production technologies, the production of steel structures was chosen, which accounts for more than 50% of the total production of the plant. When determining the "problematic" places of flow by the RCC employees and the VENTALL LLC working group, the following vulnerable places were identified:

• large number of unnecessary movements and movements;
• equipment downtime and waiting,
• overproduction;
• Surplus inventory in reallocation (work in process)
• frequent equipment malfunctions.

The most "problematic" place in the production of steel structures was unfinished production, that is, a product that has not passed all the processing stages. This is the frozen money of the enterprise, so the most active work was carried out to reduce reserves at alterations. But no less attention was paid to the formation of a high-level production system, discipline and improving the efficiency of working personnel.

Based on the results of the analysis of the current state of the pilot flow, the following were implemented at the enterprise:

• 5C-system of an effective and safe workplace, aimed at improving the efficiency of employees, improving their discipline and functionality.
• Production analysis that monitors the progress of the production plan.
• Stand-alone hardware maintenance that reduces the number and amount of downtime for repairs. Personnel were involved in constant monitoring of the condition of the equipment, a lean attitude is actively being introduced. A service standard was also developed and the responsible ones were appointed.

Thanks to the active participation of employees, we have shown that lean production technology brings results and is effective. Therefore, we plan to attract to the national project other production areas. The replication process has already been launched on a neighboring stream of assembly and welding of products, working groups have been created from the heads of other departments, "said procurement workshop foreman Alexei Shataev.

The company plans: to reduce unfinished production by 50%. Also, for six months of implementation of the national project, it is planned to reduce the time of production processes by 35% and increase production by 25% per employee. At the same time, according to representatives of VENTALL LLC, an increase in standards does not imply a reduction in staff. The concept of lean production implies the release of human resources in order to redistribute them to other areas, by retraining employees and preserving jobs.

The expected economic effect of the transformations is more than 100 million rubles, "said Ivan Golikov, project manager at the RCC. And VENTALL expects to achieve this indicator.