Introduction
Limea-Fisma S.p.A. is an Italian company specializing in the production of lightweight metal packaging. For over 75 years, Limea-Fisma has been a benchmark in the sector, offering steel and tin packaging solutions for industry, with a strong presence on international markets.
The problem
Undertake a review of the company’s production lines with a view to Lean Manufacturing in order to achieve a significant increase in productivity through the reorganization of production flows.
The organizational redefinition of processes also includes evaluating the possible introduction of automated warehouses and the synergies resulting from the construction of a second production plan, adjacent to the existing one.
The goal is to implement a “Kaizen Program for Excellence” that includes:
Optimize production and process flows in the current plant in order to increase productivity through a study that also includes an assessment of the introduction of an automatic warehouse for semi-finished and/or finished products, which is currently lacking.
Define the activities and processes for a second production plant, to be built in the near future.
The solution
“Technology Consulting” is the tool that MADE makes available to manufacturing companies to provide concrete support for the implementation of technological, organizational, and management solutions designed to improve business processes with a view to Industry 4.0, through consulting and feasibility studies.
Based on the study conducted by MADE4.0 consultants and the comparison of hypothetical layout scenarios for the allocation of production lines (new and existing), the best solution for increasing and streamlining the company’s productivity has been identified.
The project will enable the development of a 2D simulation of the layout capable of analyzing bottlenecks and, in general, increasing production capacity by ensuring optimal process flow, from the entry of raw materials to the exit of the finished product from the factory warehouse, as a tool to support the decision-making process.
Desired impacts
With the proposed project, Limea-Fisma expects several significant industrial benefits and impacts, particularly in terms of competitiveness, safety, and sustainability.
The optimization and re-engineering of processes from a Lean perspective, leading to a reduction in internal transport and transit times, will result in lower energy consumption, with significant impacts on OEE and energy consumption.
There will also be a reduction in the risk of obsolescence and damage due to transport, as well as the creation of space for further automation of business processes, together with improved traceability and selectivity of goods.
Benefits for the company
In terms of expected results, production is expected to increase by 10% in the current plant, thanks to the reengineering of processes with a view to continuous improvement, and a further increase in production capacity and process standardization with the new plant, which will have synergistic processes and activities with the current one.
Thanks to the improvement initiatives that emerged from the design study, it will be possible to implement a warehouse renovation program, resulting in optimization and reduction of space required for storage of materials on the production line and in passageways, with benefits both in terms of operations and in terms of health and safety risks for operators.
