Daily and Breakthrough Kaizen Applications and Total Productive Maintenance
Driving maintenance excellence through Kaizen, 5S, visual management and Total Productive Maintenance.
Completed
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Project Overview
Project Components
We conducted an analytical assessment of the current situation at Alexandria Carbon Black’s electrical, mechanical, tooling and planning departments. We designed and implemented visual management boards and performance indicators, established periodic assessments to ensure Kaizen adherence, applied 5S and visual management, and delivered TPM training.
A. The Challenge
The plant needed to enhance maintenance efficiency, standardise processes and develop staff capabilities. Existing practices lacked visual management, performance metrics and structured improvement routines.
B. Our Solution
We introduced visual dashboards and KPI boards, conducted regular assessments to identify improvement opportunities, applied 5S and Lean methodologies, and trained staff in Kaizen, value stream mapping, waste reduction, analytical and statistical problem solving, standardisation and Total Productive Maintenance.
C. Key Achievements
The project improved maintenance reliability and efficiency, enhanced adherence to standards, empowered teams with continuous improvement skills and established a sustained TPM program that supports operational excellence.
Project Summary
Project Information
Client:
Alexandria Carbon Black
Value:
500,000 SAR
Start Date:
August 5, 2019
End Date:
December 10, 2020
Duration:
Sixteen months
Project URL:
Status:
Completed
Additional Information
The Client Phone :
+20 3 4770 102
The Client Email :
sabyasachi.patnaik@adityabirla.com
Taxonomies
Service Area:
Quality and Institutional Excellence
Client Sector:
Corporate & Industry