In 2011, a revolution called Lean began in SAC Screen Printing.
The decision to apply this methodology that is so successful among metalworking companies to the screen printing industry as well was born out of a desire to improve our competitiveness in a market characterized by increasingly rapid times and increasingly complex requirements.
We also felt the need to find an effective, streamlined and agile methodology due to the “complex” and heterogeneous nature of our production, which is characterized by the simultaneous use of different materials, machinery and techniques, with separate timelines and procedures.
Years later, we can say it: the Lean revolution has borne fruit, in every area of the company!
THE LEAN REVOLUTION IN A SCREEN PRINTING COMPANY
LEAN AND PRODUCTION AREA
Lean has made a significant improvement from a production flow standpoint, eliminating bottlenecks and wasted time.
From machinery repositioning to tool management, the production area has been completely reconfigured by improving the whole way. Now everything has its place and the process is constantly optimized by the work method itself.
One example is what we internally refer to as the “supermarket,” which is the shelf with production totes broken down by processing. This solution not only optimizes management but also allows bottlenecks to be identified so that actions can be implemented to eliminate them.
LEAN AND WAREHOUSE
The warehouse area was reconceived with the kanban system and according to Lean principles, first and foremost simplicity and rationality. By eliminating the superfluous, we gained a lot of space and gained in order and cleanliness.
The procurement and movement of goods is now a systematized and extremely fast process. The complete computerization of the warehouse also ensures seamless integration with suppliers and production, enabling real-time monitoring of the availability of stored components and ongoing activities.
INTEGRATED MANAGEMENT
In conjunction with the implementation of Lean, we invested in an integrated management system that keeps the administrative, commercial and production parts in constant synchronization. This choice has streamlined and automated the work of all departments and eliminated waste of time and paper.
As each new bid arrives, the computer system saves time in setting up and fine-tuning machinery by automatically initiating all the various steps in the process.
MORE EFFICIENT OPERATORS
For the proper application of Lean, in SAC Serigrafia as in all companies that have adopted the methodology, operators play a key role. Each of our operators is an active participant in improvement and is encouraged to point out critical issues and propose solutions.
This makes it possible to create optimal process standards with the definition of procedures that are common to all and created in common by all. In fact, thanks to terminals installed at each production station, synchronization with other departments is continuous and in real time.
It is a great team effort, and thanks to Lean, everything is easier.
RELATIONSHIP WITH SUPPLIERS
In today’s dynamic market, suppliers play an essential role in a company’s competitiveness and reliability. Therefore, it is important to make coordination and shared improvement systematic.
Thanks to the daily efforts of our suppliers and constant contact with SAC Serigrafia’s quality manager, we continue to make procurement more effective, so as to be more timely in responding to customer needs.
COSTUMER EXPERIENCE
Reducing work schedules allows the time saved to be invested in new activities and projects. It was natural for us to choose to apply Lean continuous improvement to the services andexperience offered to our customers as well.
We started from a thorough analysis of our clientele with the goal of:
- offer better service
- Ensuring even more customized solutions
- Improve satisfaction of new and retained customers
We have realized that for many of our clients, reliability and performance is critical, for others the ability to create customized time and cost-saving solutions. Still others ask us to work together on highly innovative projects.
To each we now offer “needs-based” coaching, but to all we offer what for us, and we believe for them as well, is a fundamental value: simplicity.
And for that, Lean has been very helpful.
SCREEN PRINTING AND LEAN: THE RESULTS
The application of Lean in SAC Screen Printing has led to greater accuracy, efficiency and coordination in daily management.
We have been able to sharply reduce costs and lead time, providing our customers with more certainty and timeliness.
Thanks to Lean, we can also offer increasingly customized products without the introduction of new techniques or the use of complex techniques harming or slowing down the flow.
In short, we are happy with this revolution of ours and to have shared the experience with you!
But the work, just as Lean requires, continues…
SAC Serigrafia’s journey with Lean was also covered in the dissertation of Giuseppe Spagnoli, of Tor Vergata University.
