Graphic Packaging International slims costs with lean manufacturing: Firm taps into employee creativity and innovation

Abstract

Purpose

This paper aims to describe the benefits from lean production at the UK manufacturing plant of Graphic Packaging International.

Design/methodology/approach

The paper outlines the origins of the reforms, how they were introduced and the results they have achieved.

Findings

The paper reveals that improvement teams were formed and trained using a Score (select, clarify, organize, run and evaluate) method of maximizing return on lean improvement projects. Machine operators not only highlighted key areas for improvement, but also signaled the beginning of a dramatic shift in the company culture.

Practical implications

The paper reveals that the Bristol plant has saved £175,000 a year, which represents a 3:1 return on investment. The assignment has increased the manufacturers' productivity by 90 percent, enabling better customer service and a significant reduction in overtime.

Originality/value

The paper highlights the ways in which lean manufacturing helped the plant to cut waste and cost, increase the speed of manufacturing and improve the customer experience.

Citation

(2009), "Graphic Packaging International slims costs with lean manufacturing: Firm taps into employee creativity and innovation", Human Resource Management International Digest, Vol. 17 No. 7, pp. 21-22. https://doi.org/10.1108/09670730910996527