How to maintain production efficiency in high-stakes extrusion 

For extrusion houses, kaizens can be targeted toward steps throughout the production process. On an extrusion line, a focus on organization and decluttering of individual workspaces can help reduce set-up times by organizing tools and dies for faster access, quicker changeovers and fewer errors. Excellent organization can also help prevent material contamination or cross-mixing from poor housekeeping. Elsewhere, kaizens focused on the identification and elimination of bottlenecks, overproduction and idle time can smooth production flow and increase throughput without additional capital investment.  

Beyond the production floor itself, kaizens can be aimed at improving order-intake processes, invoicing, customer service processes and more. The results for the business can be impactful — more-efficient order intake can directly shorten customer lead times by allowing the organization to proceed with production faster and more efficiently.  

There are intangible benefits to these activities as well. At Kent Elastomer Products, all employees have trained on and participated in kaizens and other activities — this has strengthened the level of trust and communication between employees, departments and managers. For any plastics extruder, these processes can further help keep extrusion efficient. 

Adherence to optimal procedures

Part of serving high-stakes markets involves adherence to certain industry standards that govern specific procedures and expectations. Indeed, lean manufacturing practices and adherence to such standards often go hand in hand — and both are key to more-efficient production and scalability for extruders. 

For example, ISO 13485 standard is a globally recognized quality-management (QMS) standard specifically designed for medical device manufacturers and related services. A plastics extrusion processor servicing these markets must adhere to the standard, meeting the necessary requirements for a comprehensive system to ensure consistent design, development, production, installation and delivery of medical devices that are safe and effective. The standard focuses on risk management and risk-based decision-making, design and development controls, supply chain management, regulatory compliance, product traceability and recall procedures, and document and record controls. 

Manufacturing facilities achieving this standard are regularly subject to surprise audits from standards administrators. These audits are typically very thorough, as inspectors work to ensure that the facility maintains proper procedures at every point of production. Here, lean activities that have been implemented in service of standardized procedures can help contribute to adherence — no matter when an inspector might arrive at your facility.