Certification of internal lean production instructors was held at the Protei plant

2025

Certification of Internal Lean Instructors

The certification program of internal lean production instructors has been completed at the production site of JSC Protei. The company, which joined the federal project "Labor Productivity" in 2025, has adapted training materials to the peculiarities of its own production processes and has already conducted a series of trainings for employees. This was announced on August 15, 2025 by the Regional Competence Center of the Kaluga Region.

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Фото: Regional Competence Center of Kaluga Region

The goal of the initiative is to strengthen internal competencies in the field of continuous improvement, reduce costs and increase the efficiency of production operations. Certified instructors will now play a key role in spreading lean manufacturing principles across the company.

We rely on internal expert potential, - said the project manager Yevgeny Eroshin. - The instructors prepared by us not only have deep knowledge, but also perfectly understand the specifics of production. This makes the training as practical and effective as possible.

Participants of the trainings noted the high practical value of the program.

The training was enjoyed. At the beginning, he did not even have a clear idea of ​ ​ the 5S system. It turned out that intuitively already applied some elements. Now the realization has come - how exactly I want to organize my workplace: both in the office and in the workshop. We will implement the acquired knowledge, - the mechanical engineer of the plant Roman Sukharev shared his impressions.

Results of three months of the project

At the plant, Zavod Protei JSC summed up the results of three months of the federal project Labor Productivity (implemented under the national project Effective and Competitive Economy). The operator of the national project is the Regional Competence Center (RCC), operating on the basis of the Kaluga Region Business Development Agency, which announced this on May 29, 2025.

To optimize, a line for the production of plastic products was chosen - a key area that provides the bulk of the company's revenue.

During the first phase - "Diagnostics and Planning" - the working group recorded more than 64 problems that reduced performance. About 60 measures were developed to eliminate them using lean tools:

• 5C
• standardized work
• SMED
• production analysis

A bottleneck was identified, limiting the pace of production and reducing productivity by 20%.

The action plan is aimed at:

• Improved storage of finished products - The necessary product can be found in less than 20 seconds;
• Shorten search time for product information
• Personnel release;
• increased output;
• shorten the search time for injection dies - thanks to address storage and an electronic accounting system, you can find the desired tool in less than 20 seconds.

Many thanks to the whole team! No matter how prepared we are and no matter how dynamic we are, there are always moments that we can miss. You know the best practices as professionals with experience and knowledge from other businesses - and that's invaluable. Thank you so much for sharing your experience. I perfectly understand the importance of the changes being implemented, but I want to appeal to those managers who have not yet participated in such projects: be sure to try, look inside - see how it works in practice. The perception of innovation often begins with rejection. Our task is to explain to employees that these tools are really useful, show our own engagement and together feel the real result of our work. This is an excellent practice, especially with such serious support at the federal level! - Pavel Mishin, Production Director of Proteus Plant JSC, shared his impressions.

At the next stage, where the action plan for obtaining results will be implemented, specialists will continue to work on the creation of a reference area, including a stamp storage warehouse and an ASB automatic machine, organize an information center, calculate the economic effect and certify lean production instructors.

Process Factory Training

Employees of the plant JSC "Proteus Plant" were trained at the Process Factory. At this training site, participants in the federal project "Labor Productivity" study lean production tools and immediately use them in practice when assembling a real device. This was announced by the Business Development Agency on May 23, 2025.

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Фото: Business Development Agency

The training was conducted by specialists from the Regional Competence Center (RCC), which is the operator of the national project. The center operates on the basis of the Business Development Agency of the Kaluga Region.

During the training, the plant team assembled gas gearboxes, optimized assembly areas, QCD and logistics. According to the results of the training, they managed to reach virtual earnings in the amount of 109,500 rubles - an indicator that demonstrates the potential economic benefit from the introduced improvements.

This training has become very useful, despite my extensive experience with lean technologies. Many processes are familiar to me, but it is always interesting to look at them from the other side and find a point to optimize. I also note the well-coordinated work of the entire team! - Raviya Miftakhutdinova, Deputy Chief Engineer for Production Preparation at Zavod Protei JSC shared her impressions.

As of May 2025, the Proteus Plant team is completing the Diagnostics and Planning stage, during which key measures aimed at improving labor productivity were identified. The company has established a project office, as well as almost completed training of future lean production instructors who will implement and replicate new effective practices.

Labor Productivity Project Start

The team of Zavod Protei JSC has begun implementing the federal project Labor Productivity, which is being carried out under the national project Effective and Competitive Economy. The regional competence center, operating on the basis of the Business Development Agency, began to introduce lean production tools at the enterprise. RCC specialists have previously trained the project working group on the basics of lean production. This was announced by the Business Development Agency on March 12, 2025.

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Фото: Business Development Agency

A kick-off meeting was held at the enterprise, where they talked about the directions of work. The working group took part in trainings from RCC experts, where it received primary knowledge about the basics of lean production, 5S in production, production analysis, mapping, implementation of the improvement project.

We are glad to join this project and are ready to actively work to improve the quality of products produced by the plant. Our goal is to introduce the principles of lean production among the maximum number of employees of the enterprise, which will allow us to count on a significant increase in productivity in the selected area, "said Pavel Mishin, Production Director of Plant Proteus JSC.

After the primary training, the team will go through the "Diagnostics and Planning" stage, where the reference area will be determined. After that, under the guidance of production masters, digitizations of the current states of work processes will be performed. Within 3 months, the company will then establish a project office of instructors-employees of the company for the subsequent implementation of changes and replication of successful experience.