RDM Group reports improvements at Barcelona cartonboard mill after one year of Lean Manufacturing Program, including halving customer complaints due to lumps, water treatment improvement, reduction of board machine downtimes due to unplanned standstills

April 17, 2023 (press release) –

After one year, our Lean Manufacturing Program leads to great results in RDM Barcelona Mill:

• Quality: 50% reduction in customers’ complaints due to lumps;
• Sustainability: improvement of water treatment;
• Time efficiency: reduction of Board Machine downtimes due to unplanned standstills;
• Shop Floor Management: mill’s governance improvement, based on visual management.

ExcellenceONE is our Lean Manufacturing Program launched in 2021 with the aim of perfectioning production processes and building a well-structured working model, to maximize profits while limiting losses and waste.

The program is built up on 5 pillars:

• Process Improvement;
• Shop Floor Management;
• 5S+ Standardization;
• Problem Solving;
• Manteinance.

The implementation starts with a diagnostic project in the mills – at both organizational and production process levels – to identify opportunities of improvement. Then, the phase of Process Improvement begins, consisting on the launch and management of a series of improvement projects, the “Lean Initiatives”. The Lean Initiatives are managed through a sustainable management system where objectives and responsibilities are clearly defined, actions are planned and KPI’s are monitored to quickly react to deviations from standards.

ExcellenceONE was first launched in RDM Arnsberg and RDM Barcelona Mills, and it is currently being implemented also in RDM Santa Giustina, under the supervision of Mauro Carminati, Group Lean Manager, and his team of Operational Excellence Managers, the ambassadors of Lean Manufacturing of the Group: Mireia Rius, Sven Schumacher and Enrico Cesarotto. This year also Villa Santa Lucia, Paprinsa, and Ovaro Mills will follow.

Following the audit process by the LRQA Certification Body, accomplished on March 30, RDM Magenta sheeting center obtained ISO 45001 certification, with a very positive rating on health and safety.

Pro Carton – The association of carton and cartonboard manufacturers, has joined a newly formed alliance – Circular Choices – to increase its members’ leverage and influence on the market.

RDM Group is focusing on implementing responsible water management practices, recycling and reusability of water, investing in technological solutions aimed at further closing the process water loop, and improving the quality of water discharges.

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