Hologic

Kaizen Facilitation for Filling Processes

Facilitated lean manufacturing improvements across two Hologic sites, driving efficiency, reducing waste, and cutting product rejects through Kaizen, VSM, and CAPA implementation.
HOW WE HELPED
  • Led cross-functional Kaizen events focused on the optimization of filling processes at two manufacturing sites.
  • Conducted Value Stream Mapping (VSM) of the current state to identify bottlenecks, inefficiencies, and waste across the production flow.
  • Facilitated root cause investigations for process failures and implemented effective Corrective and Preventive Actions (CAPA) to reduce recurring issues.
  • Improved workplace organization, resulting in a 30% enhancement in layout efficiency and smoother material flow.
  • Strengthened supplier management and implemented controlled delivery schedules, significantly reducing inventory storage costs.
  • Established a High-Performance Team model to monitor Key Process Indicators (KPIs), ensuring sustained process control and proactive issue resolution.
  • Fostered an environment of continuous improvement by empowering floor employees to propose and own actionable ideas, including a reward system for implemented solutions.
  • Achieved a 20% reduction in product rejects through process standardization and robust failure analysis.
  • Layout Efficiency Gain

    30%

    Reject Rate Reduction

    20%

    Sites Involved

    2

    Methodology

    Kaizen & VSM
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    workshop meeting