A factory evaluation that combines on-site assessment and benchmarking performance levels to give a clear picture of the potential for improvement.
Examples of benchmarking would include:
I. Furnace: kcal/kg of glass melted; tons melted per m2
II. Forming: pack to melt percentage; defect analysis; forming practises
III. Moulds: units produced per blow mould; set sizes; cavities per mould repair worker
IV. Machine Repair: variable equipment set up; Job change performance
V. Productivity: people per feeder; tons packed per person
Experience shows that a factory assessment proves that continuous improvement is always possible. Even the best factory can be better!
NNPB brings benefits and competitive advantage but it is a demanding process with high precision, control and expertise needed to assure quality and production efficiency.
As markets develop or customers seek new markets, the need for lightweight containers becomes apparent. Experienced glass makers recognise that NNPB is a step up from normal production and that there are critical factors for success
clearPerformance provides support in 3 key areas:
AND we also advise on progressive light weighting using blow/blow to meet customer needs and as a progression to NNPB.
In the economic climate of today there is the need for flexibility and reduced inventories and Job changes are a critical part of this.
Success will come from a focus on improving job change performance.
clearPerformance offers a job change improvements program that is tailored a factory’s needs.
Success is measured in improved job change time (TI), ramp up (T2) and overall Pack to Melt.
Moulds are a significant cost and their quality directly impacts product quality and pack to melt.
clearPerformance provide expertise to improve the areas crucial to mould repair performance.
Quality product and production efficiency depends upon
The clearPerformance program focuses on:
Good “bottlemaking” is at the heart of a successful glass factory and clearPerformance has particular expertise in this area.
Trouble Shooting
clearPerformance experts have successfully provided support to significantly lift the performance of particular jobs, often based on the DPT framework:
Speed increase
Increasing the speed of a job is one of the quickest ways to improve productivity. clearPerformance uses benchmark data and forming expertise to speed up machines and increase output.
Lightweight and Right-weight
Experience shows that many companies are giving glass away by running heavier than needed or heavier than specification.
clearPerformance advises on light-weighting to the optimum weight capacity ratio using the existing forming process. This saves weight/cost and has the additional benefit of allowing speed increase.
The team has vast experience in the design of new facilities and of managing major projects.
Recent involvement in three new build projects has given a knowledge that is current and of value to our clients in:
The tangible results have included: reducing a total project cost by over 20%, changing the proposed line up of machines to fit the job mix and redesigning the plant layout for operational efficiency and cost reduction. Major projects like furnace rebuilds require careful planning, control and execution.
clearPerformance project offers support through:
clearPerformance has a record of success in completing projects that prove our differentiation:
Job Change Improvement
Mould Operations
Plant Reviews
NNPB start up
Using wide experience and hard acts, clearPerformance will enable bench marking companies’ operations across a spectrum of activities and give a new perspective on what is possible.
The Glen, Knutsford Old Road
Stockton Heath
Warrington
WA4 2L
United Kingdom
Derek Whiteside:
derekwhiteside@clearperformance.co.uk
Mobile: +27 (0)76 114 0397
Steve Hammond:
stevehammond@clearperformance.co.uk
Telephone: +44 (0)783 628 8974