AEG

Cooper Coated Oil

Cooper Coated Oil

Cooper Coated Coil are international specialists in the production of precoated metals to the housewares, building, automotive and white goods manufacturing sectors. Having invested in a new multimillion pound coating line they were experiencing start up issues that were threatening to adversely impact their customers. AEG were engaged to undertake an improvement programme.

To ensure that the benefits were lasting, a Continuous Improvement team was established to address the problems together. An approach inspired by 6 Sigma’s Define, Measure, Analyse, Improve and Control methodology was used to concentrate the available resource onto the most significant problems.

The improvement activities included redesigning and re-building critical parts of the line, developing Standard Operating Procedures, changing working practises, adding instrumentation to allow operators to understand what was happening within the line etc.

The result so far has been a 65% reduction in scrap and and a 30% increase in throughput.

In order to increase the line Availability maintenance systems have been established. Control of spares, scheduling of work & a scheduled maintenance system have effectively moved the operation from reactive to proactive. The result is Availability has risen from 55 to 85%.