Lean technologies helped Kaluga pennostekl manufacturer increase labor productivity

2024

Results of participation in the national project "Labor productivity"

At the plant for the production of thermal insulation from foam glass "ICM Glass Kaluga" summed up the results of participation in the national project "Labor productivity." The operator of the national project is the Regional Competence Center (RCC), operating on the basis of the Business Development Agency, which announced this on December 23, 2024.

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Фото: Agency for Business Development of the Kaluga Region GAU

During the participation in the project, 8 trainings were held, 7 employees were trained in the basics of lean production, two became instructors, having successfully passed certification. After the analysis, bottlenecks in the flow were identified - the "furnace" section. The working group recorded more than 27 problems in the production process that reduce productivity. To eliminate the problems, about 44 measures were formed to eliminate them.

{{quote "Based on the results of the active stage of the presence of RCC specialists at our enterprise, it is safe to say that expectations from participation in the" Labor Productivity "project were generally met. We have groped areas to improve production efficiency, improved staff skills, outlined an improvement plan and have already partially begun to implement it. In general, this is not a one-time project, but a methodology of constant improvements, which, we are sure, will bring its results in the medium and long term, - shared his impressions Alexander Klyuev, General Director of ICM Glass Kaluga LLC.}}

Thanks to the implemented improvements, it was possible to reduce downtime during the movement of loaders and increase the volume of shipments by moving the loading line to the center of the site:

• before participation in the project - 103 meters,
• after - 56 meters (+ 63, 48 cubic meters per shift)

Also in the near future - a reduction in the time for packing in bags with 246 to 160 minutes, the cost of purchasing materials for labeling from 600 thousand to 140 thousand rubles a year (- 460 thousand rubles a year), an increase in production at the furnace site. The expected economic effect in the implementation of all tasks and events is 58 million 890 thousand rubles.

I thank the team of Ai Sea Glass Kaluga LLC for their active participation in the project. We are ready to continue to provide methodological and consulting support so that the approaches of lean production extend to all areas of the plant, - summed up the general director of the Business Development Agency Nikolai Tubenshlyak.

Joining the Labor Productivity Project

The 100th line in the list of participants in the national project "Labor Productivity" in the Kaluga Region was taken by the plant for the production of thermal insulation from foam glass "ICM Glass Kaluga" (ICM Glass).

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Фото: Kaluga Region Business Development Agency

The project operator in the Kaluga region is the Regional Competence Center (RCC), operating on the basis of the Business Development Agency, which announced this on May 3, 2024.

The company "ICM Glass Kaluga" has been operating since 2013 and is located in the Vorsino industrial park in the Borovsky district. Broken glass is used as raw materials at the enterprise, which allows solving an important environmental problem - the disposal of solid household waste.

Over the year, the company processes more than 20 thousand tons of glass glass. But despite the high results, the plant management decided to join the program that will help improve production processes.

Taking into account the fact that the national project "Labor Productivity" has proven itself from the best side and confirmed its success at many enterprises throughout Russia, we believe that participation in the program will definitely allow us to realize the expected goals and objectives, increase labor productivity, the qualifications of our personnel, business efficiency in general and the competitiveness of our products on the market, Alexander Klyuev, General Director of ICM Glass Kaluga LLC, shared his expectations.

After the initial training, the team will go through the "Diagnostics and Planning" stage, where problems and reserves of the production process will be determined. After that, the project team, together with RCC experts, will form a plan to disclose reserves for improving production and implement it in the next 3 months. Also, from among the employees of the enterprise, lean production instructors will be trained, who will be able to train colleagues who are not included in the pilot project working group for further replication of experience to other processes.