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Confirm programe scope: select filling area to optimize its operational cost for this Chinese customer.
Then build up activity based operational cost structure map to identify improvement opportunity. For this American plant, redundant laber was found to be optimized and the effeciency of filling machine needs to be improved using one methodology to calculate the equivalent point of input and output.
Third, setup KPI system and design losses attacking route to improve the availability, performance and quality.
Finally to confirm the improvement and cost saving. Over filling of the products was reduced in this plant in which there are 10 lines with OEE being 57% (World class OEE is 85%) and the annualized plant saving is 2.99 million RMB.