Striving for Improvement: Explore Our Meaningful Work of our Process Improvement Department

Continuous improvement is an important principle within our role as an injection molding subcontractor. Our Process Improvement Analyst, Omer Ben David, leverages an in-depth understanding of the company's departments to implement a culture committed to continuous improvement
October 29, 2023

As a subcontractor specializing in injection molding, we strive to excel in delivering efficiency, top-notch quality, and a professional approach. This presents an opportunity for you to become acquainted with Omer Ben David, the driving force behind optimization processes at Rion. With a track record spanning over two years, Omer systematically identifies areas for improvement, devises effective solutions, oversees the implementation of changes, and his efforts consistently translate into better productivity.

Omer entered this important role after a seven-year journey at Rion, where he took on various tasks in production planning and management for the molding department. His experience and his education as an industrial and management engineer assist him to form strong partnerships with colleagues throughout the organization. This teamwork leads to effective collaboration and impressive outcomes. To showcase this, we present a few projects that demonstrate these successful collaborations.

Transitioning to multi-use, sustainable packaging

The plastic industry often gets a lot of negative attention, especially when it comes to packaging. Disposable products create a lot of plastic waste that harms the environment. Here, we want to talk about an important customer who gave us a task: he needed packaging for 2500 parts, in disposable cardboard boxes with plastic bags inside.

Our warehouse manager at the Plastokit site, Roman Acheildayev, suggested coming up with a better packaging idea. Both he and Omer delved into the matter. “We looked at what the customer needed and suggested using plastic crates that can be used multiple times. This method is much more sustainable, it eliminates the need to buy/waste cardboard boxes. We were able to pack 15,000 parts in one crate, six times more than before. This smart packaging also needs fewer people to handle,” Omer says. “We earned back the money we spent on this idea in just three months, and it’s an eco-friendlier option for both us and our customer,” he adds.

“Less is More” – Finding Unnecessary Quality Tests

Making work more efficient doesn’t always mean adding new procedures or changing things. Sometimes, it’s about eliminating unnecessary actions. One area that often suffers from excessive practices in the industry is quality control. Redundant parameter tests or excessive testing actually prolong work without yielding benefits.

An analysis of our manufacturing departments revealed that each product underwent testing twice: near the production machine and at the quality control station. Analyzing the timing of these tests allowed us to eliminate the initial test while still swiftly detecting faults if they occurred. This way, our line workers could redirect their time towards other crucial tasks.

Implementing Digitization Across the Production Floor

Another significant project we’ve previously highlighted is the integration of tablet usage in the Molding Department. Due to its success, we extended this implementation to additional departments: Inserts, Maintenance, and Warehouse.

“Currently, all these departments are operating with tablets. Employees input real-time data, granting access and analytical capabilities while reducing manual documentation”, says Omer. “For example, the maintenance team can initiate and terminate service requests while updating the allocated hours for each task. Similarly, in the warehouse, shipment documents can be swiftly scanned upon arrival, before the goods are put in storage. The system triggers emails to the requester, ensuring time-saving, loss prevention, and prompt handling of faulty goods. In the Inserts Department, we’ve increased efficiency through automated reminders regarding maintenance for active molds, all accessed via the tablet. The system enables generating reports on mold maintenance, that are accessible to Rion’s clients.”

Every Day Brings New Challenges

“The daily routine of an engineer in the Process Improvement Department is fascinating, with each day presenting unique challenges. Whether it involves production planning, implementing cross-organizational processes, working near the injection machine, or conducting quality tests, this job is very diverse. I am delighted to bring value to different departments, fellow employees, and of course, our customers,” Omer concludes.

Picture 1: Omer Ben David, Rion’s Process Improvement Department Analyst, next to reusable plastic crates – a smart and sustainable packaging solution.