Lean Sigma Offering Further Efficiencies at Benson Group

December 2010

Following hard on the heels of recent announcements regarding Benson Group's world first with its attainment of the BPIF's ISO12647-2 colour standard certificate, the company has also released details of its first year's progress with Lean Sigma, a structured programme to create operational improvements. The programme is being managed by David Midgley, Operations Manager at the company's Bardon, Leicestershire plant.

What is Lean Sigma? Lean manufacturing is an approach that seeks to improve flow in the value stream and eliminate waste. At Benson Group it is being combined with Six Sigma, a powerful framework and set of statistical tools used to uncover root causes in order to aid understanding and reduce variation. The combination of both approaches provides a structured improvement as well as effective tools to solve problems.

Having joined the business in August of 2009 following a working lifetime in the textile industry, David Midgley, Operations Manager, feels he is now able to describe the benefits that the first year's worth of Lean Sigma has produced for Benson Group, with the obvious highlight being a double digit growth in print production at the company's flagship site in Bardon, Leicestershire.

"We need to view this as year one of a four year plan to implement Lean Sigma throughout the whole of the plant," said David Midgley. "Year one has been very much about getting the basics in place and getting people to buy into the project. Overall equipment efficiency (OEE) is a key part of the process for a manufacturing company because they can see real results very quickly. We have already seen a double digital improvement in terms of printed sheets on the floor, and that is a key measurement for the overall success of the business. Once you can demonstrate that sort of improvement, both senior management and team leaders around the factory are on your side!"

Each piece of equipment has its own record book, and each operator has their own individual programme including production targets. Statistical analysis boards are in place throughout the production area in order for shop-floor staff to see exactly how each part of the business is performing, including which shift is posting production records.

David has been surprised at the similarities between his textile background and the demands of printed packaging. "There is not a huge amount of difference between the two industries really; both have their machine operators, their production equipment, and the ever present customer demand for faster production! Certainly print packaging production has to be one of the fastest moving businesses in the world, but like most manufacturing it's heavily focused on the people, systems and culture that exist in the production plant."

In addition to production positives the company expects to achieve further green and environmental benefits from the programme, including even more waste reduction. "The "5S" strategy is a key part of the Sigma element of the programme; it aims to reduce waste, simplify the working environment, and improve efficiency, safety and quality. The strategy is based on five Japanese words which roughly translated into English mean: sort, set, shine, standardise and sustain," explains David. "We have put our 5S strategy in place, and we are currently working through its requirements."

A training plan is currently being formulated with nearby Loughborough College for both external and internal training over the four year plan. All workers will be invited to take part in the programme, which includes NVQ's at level 2 and level 3, with the first round of courses expected to begin in January 2011.

Commenting on the use of the Lean Sigma approach, Mark Kerridge, Managing Director of Benson Group, said: "Along with rapid growth and successful expansion it is vital to pay attention to every member of the team, and every small part of the manufacturing process. That, in turn, helps us as a business to identify any potential problem areas within production. David, with his utilisation of the Lean Sigma approach, is helping us as a company to do just that, and we are delighted with the results that are already being clearly illustrated."

About Benson Group

Benson Group is one of the UK's leading privately owned printed carton suppliers, producing packaging product for both the food and pharmaceutical industries.

Headquarters are in Bardon, Leicestershire, where the company owns 130,000 sq ft of production and warehouse space. Benson Group achieves annual sales in excess of £93 million. Food manufacturers are the main customers at Bardon and for the company's two North East facilities in Newcastle and Gateshead. These two sites have a combined total of 200,000 sq ft of manufacturing and warehouse space. The fourth site in Crewe, Medica Packaging, serves pharmaceutical and healthcare companies. It has 73,000 sq ft of manufacturing, warehouse and office space. Since 2000, investment in new plant and equipment across the four sites totals in excess of £25 million.

Benson Group creates packaging for many well-known companies, brands and retailers. Key account clients across the Group include Northern Foods, Reckitt Benkiser, Greencore, Bakkavör, Samworth Brothers, and leading supermarket chains.

For further information on the Benson Group visit the www.bensongroup.co.uk web site.

Press Information

For further information on Benson Group, its operations, or on packaging products or packaging issues please contact:

Russell J Hicks

Genesis Marketing Services (Milton Keynes)

29 Foxholes Close, Deanshanger, Northamptonshire MK19 6HA

Tel/Fax: 01908 260 662 Mobile: 07885 852 428

e-mail: Russ.Hicks@Genesis-Marketing.com