From conventional (multi steps) to In-Situ (all in one) Lean Process.
Imagined, developed and implemented , all over Europe, a new "in-situ" manufacturing process for a key and specific type of polymer (for a Fortune 300 Company serving all major Automotive Coating markets worldwide).
This lean process combines in one operation the synthesis of different types of polymers which priorly had to be synthetized and quality approved in different and independent operations.
By significantly reducing the total production time, the energy consumption, the cleaning operations, the waste, the amount of solvent needed during production, the polymer intermediates storage and transportation costs this more efficient or lean process has lowered the total manufacturing cost and generates millions $ per year in savings.
In conclusion, this invention constitutes the paragdim shift from old fashion to the new lean way these type of polymers are manufactured today: more respectful for the environment and following a lean process that provides more with less.
Green and Lean
Green Line which made possible the elimination of toxic chemical (Chrome VI )from Aluminum parts process while reducing treatment cost by 60% .
The line was developed to be as compact as possible to meet foot print constrains, within 6 months it was designed, built and PPAP on time (< 6 months between design and PPAP approval), under budget, meeting savings objective and above all above to meet customer requirements for 50% of plant turnover.
The quality of process the Green Line delivered from the start reduced the customer PPAP time that was scheduled to extend to 2 days down to a few hours see TESTIMONIALS.
Development and worldwide implementation of powerful and multilingual SPC programs
Excel / VBA based, these tailor made programs have allowed metal treatment lines in China, Italy, Mexico and the US to reach Six Sigma process capabilities and ease the passing of ISO/TS as well as all major Automotive Company quality audits.
Each program is fine tuned to match specific requirements of line process, equipment, chemistry or language (from a drop down list, the operator can select from Chinese, English, Italian or Spanish.
Graphic interfaces can adjust to all needs, they clearly identify out of control values they include day to day charts and monthly report.
