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Continuous improvement drive creates new jobs & efficiency benefits at Flexitallic

Flexitallic, the international gasket manufacturer and sealing technology specialist, has created new jobs and made significant advances in quality and efficiency as part of a continuous improvement programme across its manufacturing processes and operations.


Through the creation of the Flexitallic Operating System, its engineering team has implemented a programme of continual development within the business, which has enhanced operations and productivity across five key product divisions including Flexpro™ Kammprofiles, Sigma® and Spiral Wound Gaskets,.


The company, which has its UK base in Cleckheaton, West Yorkshire, has achieved the savings through the standardisation of production systems and delivering new processes to manage the disposal of waste across gasket material and steel sheet manufacturing.


As part of the standardisation process, Flexitallic has appointed three Value Stream Managers to devise and implement improvements across the company’s multiple gasket production lines. 


Two of the managers, lean specialist Iago Radio and former production manager Joe Verity have joined the company from the automotive industry. 


The third Value Stream Manager, Terry White, has joined the Engineering Department on secondment from his role as a Production Manager for the next 12 months. Terry will be focused on the company’s production of specialist gasket material, Sigma, which has been developed to operate in process form cryogenic temperatures to 260˚C. 


A further secondment to support Flexitallic’s continuous improvement programme comes from the Maintenance Department with Team Leader, Clive Brooks, implementing Total Productive Maintenance (TPM) processes with the development of autonomous and preventative maintenance plans. Clive is supported by apprentice engineer Cameron Hellowell.


Flexitallic instigated the programme 12 months ago with the appointments of experienced lean engineering specialists to its Engineering Department, Manufacturing Engineering Manager, Steve Flooks and Continuous Improvement Manager, Paul Voyce.


Steve and Paul have also created a suite of training and professional development for employees across the business to increase understanding of lean manufacturing processes within the Flexitallic Operating System as well as provide dedicated coaching for team leaders.


In the near future, an additional range of practical demonstration courses will be added including Standardisation for Operators and Office Lean Implementation.


Paul Voyce said: “Colleagues have really embraced the principles behind our drive for continuous improvement, which has enabled us to deliver improved efficiency across our manufacturing operations alongside gains in productivity.


“Continuous Improvement principles and processes are essential to maintaining Flexitallic’s position in the global gasket and sealing product sector.  They enable the company to remain innovative and responsive to the evolving requirements of industry whilst controlling cost and maximising productivity.”

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