Reduced Machine Downtime by 25% and Optimized 30% Factory Space through Lean Manufacturing Transformation
Client Overview
- Company: Packwell Industries (Valsad) Pvt. Ltd.
- Industry: Plastic Packaging & Container Manufacturing
- Location: Valsad, Gujarat, India
- Employees: 200+
- Products/Services: Plastic bottles, jars, and containers for industrial and FMCG clients
- Market Presence: A leading supplier known for durable, high-quality packaging solutions across India
Challenges (Before Greendot)
Packwell faced critical operational challenges that affected production flow and on-time deliveries:
- Poor Space Management: Inefficient plant layout and cluttered storage areas increased material search time.
- Frequent Machine Downtime: Equipment breakdowns disrupted schedules and delivery commitments.
- Delivery Delays: Bottlenecks and manual planning reduced responsiveness to customer orders.
- Employee Resistance: Initial hesitation to adopt new systems and Lean methods.
- Limited Data Visibility: Lack of integrated data systems hindered quick decision-making.
Our Approach
Greendot developed a structured Lean Manufacturing Implementation Plan focusing on waste elimination, workplace organization, and data-driven decision-making:
- Diagnostic Study: Conducted Value Stream Mapping (VSM) to identify bottlenecks and flow gaps.
- Strategy Design: Defined Lean objectives — reduce downtime, optimize layout, and improve delivery performance.
- Implementation: Rolled out 5S, Kaizen, Kanban, and TPM in a pilot line before scaling up plant-wide.
- Review Mechanism: Weekly performance tracking through visual dashboards and Kaizen review meetings.
Solutions Implemented
| Area | Solution |
| Equipment Reliability | Introduced preventive maintenance system to reduce unplanned stoppages |
| Workplace Organization | 5S implementation across all areas freed up 30% of floor space |
| Process Optimization | Value Stream Mapping (VSM) eliminated non-value-added steps |
| Continuous Improvement | Conducted 34 Kaizen events targeting repetitive process losses |
| Inventory Control | Kanban system enabled Just-In-Time (JIT) replenishment |
| Workforce Development | Cross-training improved manpower flexibility and morale |
Results Achieved
- 25% Reduction in Machine Downtime: Improved preventive maintenance boosted equipment availability.
- 30% Space Optimization: Reorganized layout freed up previously congested areas, enabling smooth flow and scalability.
- 34 Successful Kaizen Events: Each initiative focused on reducing waste, rework, or inefficiencies.
- Improved On-Time Deliveries: Streamlined processes led to faster order completion and higher customer satisfaction.
- Significant Cost Savings: Reduced breakdowns, controlled inventory, and efficient space utilization contributed to measurable cost reduction.
ROI: The Lean transformation resulted in an estimated ₹22–25 lakh annual savings, with a payback period of just 5 months through improved uptime and reduced waste
Why It Worked (Greendot Edge)
- Hands-On Implementation: Shopfloor-level problem solving with operator involvement.
- Cross-Functional Collaboration: Production, maintenance, and IT teams worked as one.
- Sustainable Culture: Continuous Kaizen ensured ongoing improvement.
- Visual Transparency: Dashboards and Kanban systems improved communication and accountability.
Tools Used
- 5S
- Kaizen
- Value Stream Mapping (VSM)
- Kanban System
- TPM (Total Productive Maintenance)
- KPI Dashboard
