Plascon’s 25th Anniversary marks a milestone not just in time but in transformation. Over the past quarter-century, Plascon has continuously evolved, adapting and improving to better serve its customers and employees. This year, our commitment to progress is clearer than ever as we refine our factory operations to increase production capacity and introduce new products.
Current and Future Factory Improvements
We started with a focus on improving our current state. We implemented an improved maintenance plan focused on preventing unplanned downtime on our equipment. The plan consists of a preventative maintenance schedule for process equipment and facilities, a predictive maintenance schedule for our films area, and improved equipment operator and maintenance interactions. We also identified and now stock many critical spares for our equipment. This plan has resulted in improved product quality and factory capacity since its inception.
Next, we focused on reviewing process operating procedures and updating as necessary to match the desired process. We reviewed our employee training and updated or added training to better explain to our employees what is required to complete their process. We then proceeded to improve our factory cleanliness and organization which leads to improved productivity and safety. To complete this, we used the 5S method. The 5S method stands for Sort, Set in Order, Shine, Standardize, and Sustain. These five steps are part of a system for organizing and improving the workplace to improve productivity, safety, and overall efficiency.
The 5S Method Explained
- Sort: Identify and remove unnecessary items from the workspace.
- Set in Order: Arrange items in a way that makes them easy to find and use.
- Shine: Clean the workspace and equipment to keep it tidy and safe.
- Standardize: Establish procedures and guidelines to maintain the first three S's.
- Sustain: Make the 5S principles a habit and ensure they are followed consistently over time.
To accomplish our 5S project we broke the factory into manageable sections, trained employees, and then completed the 5S. The result is a cleaner, more organized factory free of accumulated non-used items.
Employee Input & Involvement
To find ways to improve our current processes and equipment, we turned to our employees. Our employees possess the knowledge of how our current processes combine with our current equipment to produce our current products. They also know what changes could be made to improve our processes and equipment. We have tapped into our employee’s knowledge by creating an employee suggestion program. To date, we have had over 70 suggestions covering safety, process, equipment, and cleaning.
Looking to the Future
We are currently working on our future state. This includes not only new processes and equipment but also new products. To date we have procured two new automated conversion machines to convert blown film stock into various liners to suit our customers’ needs. We have plans to upgrade our blown film area to increase capacity and the types of film we can produce to better service our customers in the future. Lastly, we have been working on new products to address the needs of our ever-changing market. This is a very exciting time to be in the Operations group for Plascon!
This investment in our factory mirrors Plascon’s broader mission: consistent innovation, unwavering quality, and a workplace that fosters excellence. As we celebrate 25 years, we look forward to continuing this momentum, ensuring that the next chapter in Plascon’s journey is even more remarkable than the last. Here’s to a future built on progress, dedication, and the passion that has defined us for a quarter of a century!
