Lean brings expansion and 40 new jobs at BPI Polythene.

The Challenge

In order to fulfil BPI's bespoke contracts, the site employs a large amount of processing equipment, the volume and mix of orders had led to a build-up of finished goods, and a high level of work in process.

Plans for expansion had been discussed but there was little or no space available for development.

Alex explained what happened next: "SMAS provided a practitioner who worked with us through all levels of the factory to implement a wide range of improvement initiatives."

The Company

BPI Polythene is an indigenous Scottish company operating on a worldwide scale.

They manufacture and recycle plastics for use in packaging and other applications across numerous industry sectors. 

The Ardeer base, which is the premier manufacturing facility for polythene packaging within the group, employs over 160 staff.

How SMAS Helped

A series of awareness sessions about Lean were organised and workplace organisation and product flow projects followed to ensure the entire workforce had a clear understanding of the Lean journey - and the benefits it would bring.

After a successful trial, a roll-out plan was created to deploy the activities and learning across the rest of the site.

SMAS assisted in creating a continuous improvement process and structure. This was backed up by training in tools and techniques, and controlled via a balanced business scorecard.

Key Outcomes

The company's performance has grown considerably, turnover is up, output is up, efficiency is up, scrap is down and working capital is down.

BPI Ardeer has recorded a productivity rise whilst finished goods and work in progress stock levels have almost halved - returning valuable working capital to the site. 

The space created has led to growth plans for the site being realised, resulting in a significant capital expenditure in new equipment and the creation of manufacturing jobs.

Alex says that the key benefits that BPI has enjoyed are: "Changing the culture, improving our performance and understanding our customer needs more closely."

Asked if he would recommend SMAS assistance to other companies, Alex replied positively: "Without any hesitation. Indeed, just recently we have had a best practice visit whereby 25 companies came on-site to see the improvements we have made at first hand."

He concluded:

"SMAS has been pivotal in helping turn this site into the success that it is today."

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