Grupel’s production plant on a constant optimization process

Grupel’s production plant on a constant optimization process

At first glance, when we enter Grupel's production plant in Vagos, we feel a huge sense of organization and structure. The impact is even greater for those who knew the production area before the implementation of the new methodologies for operational management and now have their daily work made easier with the pursuit of these changes.

But what are these changes we are talking about?

In the scope of Grupel's focus on training and application of the Lean philosophy throughout the organization, it made perfect sense to start the process in production unit. Thus was started the implementation of the Lean Manufacturing management philosophy.

The Lean Manufacturing management philosophy. also internationally recognized as the evolution of the Toyota Production System (TPS), Lean Manufacturing is a management philosophy essentially focused on creating value and on the reduction of seven types of waste (7 Mudas):

  • Transport
  • Inventory
  • Motion
  • Waiting
  • Over-Processing
  • Overproduction
  • Defects

By eliminating such waste, the quality improves and the production times and costs decrease. Lean tools include  continuous process improvement processes (kaizen), production "pull" (pulled type) and failsafe elements/processes (Poka Yoke).

At Grupel in particular, we implemented supply dynamic racks systems (intermediate supermarkets) which, by being modular, the new features can be easily changed and adjusted, accompanying the changes of the storage/production line and reducing costs in purchasing new equipment.

With these changes the following objectives where fulfilled:

  • Reducing the time and optimization of the supply and collection processes;
  • Reduction of waiting times for components in the assembly line;
  • Increased efficiency of the production line;
  • Reduction of excessive movements of the employees;
  • Effectiveness of the information flow between the Logistics Department and the Production Department;
  • Promoting visual management processes.


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