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Plastic Bottle Closures B.U. of Global Co. (Mexico & U.S.)

Business Case
Capital-intensive compression molding business needs cash and lower costs for growth.
Expensive quality problem eroding market share.

Actions
Led TPS implementation in the business unit’s 4 plants in U.S. & Mexico

Results
Before
12.8%
268
0.020
2089
Metric
Scrap
Internal PPM
Customer Complaint Rate
Output per employee
After
9.0% (-29%)
170 (-37%)
0.011 (-45%)
2723 (+30%)


Summary
Claims expense dropped 71%
Grew business 10% with the same headcount & capital equipment
Won 2002 ‘President’s Award’ - best of 26 business units worldwide


“I wish to express my gratitude and appreciation for the coaching my organization and I received from Bob Bennett and the Lean Consulting Associates team while I was CEO of Ateliers Thomé-Génot in France.” - Joe Kazadi