Kaizen Institute - Success Story

Manufacturing

Daily KAIZEN™, Flow Management

Emak S.p.A.

Client Profile

Emak S.p.A. is an Italian company specializing in the manufacturing and distribution of machines, components and accessories for gardening, agriculture, forestry and industrial applications. Emak's brands are: Efco, Oleo-Mac, Bertolini and Nibbi. The product range comprises more than 250 models of chainsaws, brushcutters, lawnmowers, garden tractors, hedgetrimmers, rotary tillers, rotary cultivators, flail mowers, cutterbar mowers, transporters and similar products. Emak was incorporated in 1992 by the merger of Oleo-Mac and Efco, two companies specialised in the production of gardening and forestry machines, both of which had been active since the 1970s in the province of Reggio Emilia (Italy).

KAIZEN™ success manufacturing

Project

Emak's KAIZEN™ journey began in 2011 in the Bagnolo in Piano plant with the goal of becoming more responive towards market changes and increasing competitiveness. In 2013 KAIZEN™ was also introduced in the Pozzilli plant with the aim of improving the production process. Emak's improvement process mainly focuses on the involvement of employees in the ongoing transformation which leads to a higher return on investment (ROI).

Kaizen Institute Italy Emak youtube

"Problems are opportunities. The obstacles we have had to overcome, even the small failures have contributed to the transformation process and to the achievement of our ambitious goals."


Andrea Cosmi - Industrial Deputy General Manager


Emak S.p.A., Italy

Andrea Cosmi, Industrial Deputy General Manager Emak

Our Approach

  • Creating a new plant layout
  • Insourcing of the shipping warehouse
  • Creating a single value chain
kaizen-approach-success

Key Results

  • 50% reduction in production spaces
  • 15% increase in average efficiency
  • Improvement of workstation ergonomics
  • Risk reduction of accidents
  • Crossing time reduction of 22 days to 6 days in the molding to assembly line
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