Track: Manufacturing

Abstract

A leading manufacturer of paints and protective coatings, has faced challenges in meeting customer demands due to a declining adherence to plan (ATP), resulting in dissatisfied customers, increased costs, and a damaged reputation. To address this issue, a mixed-method research study was conducted, combining quantitative data to assess operational performance with qualitative data to understand operator challenges. Focusing on the PVA product line, the study revealed an average batch cycle time (BCT) of 44.3 hours, serving as a baseline for improvement measurement. Notably, the final quality control testing and extending stages were major contributors to BCT and ATP. Identified issues included resource allocation, communication, standardization, and process inefficiencies. The study recommends strategies for senior management to enhance operational efficiency, reduce BCT, and improve ATP. By implementing these improvements, AkzoNobel aims to optimize manufacturing processes, meet production deadlines, and regain its competitive edge, ensuring high-quality product delivery to Sub-Saharan African consumers and maintaining its status as a world-class manufacturer in the global marketplace.