Plastic Bottle Closures B.U. of Global Co. (Mexico & U.S.)
Business Case
Summary
Capital-intensive compression molding business needs cash and lower costs for growth.
Expensive quality problem eroding market share.
Led TPS implementation in the business unit’s 4 plants in U.S. & Mexico
Results| Before | Metric | After |
|---|---|---|
| 12.8% | Scrap | 9.0% (-29%) |
| 268 | Internal PPM | 170 (-37%) |
| 0.020 | Customer Complaint Rate | 0.011 (-45%) |
| 2089 | Output per employee | 2723 (+30%) |
Claims expense dropped 71%
Grew business 10% with the same headcount & capital equipment
Won 2002 President’s Award – best of 26 business units worldwide