Client – One of the largest electronics recycling firms in the US (>$100M) wanted our help and our kaizen approach.
Challenge – There was a need to reduce the cost of recycling PC and laptop hard drives, cable TV boxes and high powered computers.
Solution – we held a multi-kaizen event: 1 week with 3 teams working in 3 work cells. The teams studied material flow, processing, tools, work operation and staff in great detail. They then developed hundreds of ideas to improve & then implemented with a high sense of urgency.
Result – Each work cell was able to reduce time to recycle by at least 50%, therefore improving average productivity by 104%. Furthermore, the team size went from 11 to 5 , allowing staff to move to key needed positions.