Master Class Case Study : Vita Liquid Polymers


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The Company
Established in 1932, Vita Liquid Polymers has grown in strength to become a specialist in custom - compounding liquid polymer systems.

These are used to manufacture products such as wall coverings, floor coverings, flame-retardant coatings, automotive fuel and air filters, rubber articles and seals. The company's expertise in supplying such a wide range of different markets has given it an in-built flexibility that enables it to offer high-quality customised solutions.

The Issue

A number of reasons lay behind the company's request for a MasterClass from Industry Forum. The company was keen to improve teamwork at its highly motivated site, and it also wanted to increase the efficiency of its manufacturing procedures, with a particular emphasis on non-right-first-time occurrences.

Finally, it was actively seeking QS9000 status, a standard demanded by some of the major manufacturers in the motor industry.

The Solution
The team formed by the MasterClass made an overall analysis of production, which showed that the mixing of compounds was a major concern. They focused on a single mixing tank, and concentrated their attention viscosity, one of the key measures of the quality of a mix and a regular cause of non-right-first-time mixes.

Two main initiatives were made. The first of those looked at the work area and working procedures. Tools, gauges and other measuring equipment were relocated to their most useful positions. Mixing procedures were closely examined, and the team eliminated several tasks that added nothing to the overall procedure. 'These measures laid the foundation for sustainable improvement,' said the Managing Director.

The second initiative addressed the viscosity problem. Using proven methods, such as cause-and-effect diagrams and the 'five whys', The MasterClass took the team through a logical set of questions that identified possible root causes.

The team found 12 possible causes, and investigated each of these thoroughly. 'We've eliminated all but two of these,' said the Managing Director, 'and we have begun long-term analyses in search of further reduction in mix variation.'

Benefits
The improvements made by the MasterClass immediately halved the number of mixes that were not right first time. Vita is confident that this will be improved further by continuing analysis of the problem areas highlighted.

'The morale of the team has increased enormously. We now have a cleaner working environment and a much better sense of teamwork. Our people now have a structured approach to problem solving - they know they can make a difference.'


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