The Lean Transition

Sharing Challenges and Successes

Edson Packaging is in the custom design machinery business. This low volume, highly customized business began its transition to Lean in 2003. Early initiatives included a high level full process Value stream map, 5S, and a Red tagging event. Improvement effects included: the implementation of several Kanban boards, adoption of a daily morning meeting, strategic reduction in inventories, removal of internal stores for parts and their mgt. Along with the successes, challenges also presented themselves. Process refinements in some cases, backtracking slightly has been required. Morning meetings have been refined to make them short and sweet and focus on obstructions or delays. Making the transition requires focus and diligence to ensure that valuable time, effort, and energy is not wasted. Following up and continuing to review and monitor the changes can be a challenge when business gets busy and other priorities fight for attention.

A second phase implementation is underway. A revitalization of 5S along with training, a follow-up Value stream map and multiple, namely twelve separate Kaizen opportunities have been identified by the team with two additional independent ones underway. In a number of cases previous improvements implemented last round are being revisited for further refinement and improvement. Edson Packaging has learned that emphasis on those processes closest to the customer need to be carefully managed in balancing the “drum beat” that the other processes are aligned to support. .Measuring our processes and the variation within them is a key in designing the right sized supermarket , FIFO lane, with a pull system in order to ensure that the natural high and lows that are evident in our business are built into the plan. Another key factor for success is making LEAN a more visible part of everything we do. As improvements and questions arise, repeatedly asking the question “Will this change support LEAN?” A consistent purpose and an open mindedness to revisit previous improvements continue to support improvement at Edson Packaging.

Edson Packaging Machinery is an ISO 9001 packaging machinery company that custom designs and manufactures automatic and semi-automatic case packing machines, and peripheral devices that handle a wide range of products, from canned goods, to confectionery to converting products, and many things in between.

Edson's full service facility provides the applications, design, production, testing and support services all under one roof with a focus to maximize customer satisfaction.

Edson has supplied case packing systems on 5 continents for Fortune 500 companies, who demand reliable operation in 24 hr / 7day applications. Edson's experience includes over 1000 machines spanning 30 years.

Monika Laumann-Semenchuk, Quality & Processes Manager

Monika Laumann Semenchuk is a seasoned quality professional with hands-on experience in Continuous Improvement, Six Sigma and Quality Engineering. She has worked in a number of corporate and local management capacities, as a Black Belt as well as training and implementing statistical methods and improvement methodologies in a consulting role. She is currently the Quality and Processes Manager for Edson Packaging Machinery Ltd.