Case Studies

Company Background

Feltex Foam produces a wide range of polyester and polyether flexible, semi-rigid and rigid thermo-formable foams. Feltex Foam’s core competency is the production of technical automotive and specialised hi-tech industrial application foams in varying densities, hardnesss and colours. The business is vertically integrated, in the conversion of these foams into various dimensions / shapes for use in a multitude of applications. As a natural progression, Feltex Foam business has forward integrated into lamination technology of foam to textiles (fabric and PVC) for automotive seating and interior applications and is the authorised agent of a leading pvc manufacturer, Thainam Vynide. In addition, Feltex Foam is also integrated into the cutting and sewing of face fabrics, PVC and textile components for use predominately in automotive seating, carpets, acoustic and anti-vibration applications. Manufacturer of inert foam.

Project Scope

• The focus of this project is on the layout of the plant as the layout is not supporting the process flow and material flow throughout the plant as well as the space constraint
• Some basic training will also be provided to Team Leaders / Supervisors and Management.

Project Outcomes

• To Separate the Value Streams
• To Create Additional Space
• To Optimize Flows
• To improve the planning process

Impacts

After the problem was clearly stated, understood and defined, the team together with Dizani started on the macro Layout When the macro layout was defined, the micro layout with all detail calculations was done. Macro and Micro layouts has been agreed and signed off by Feltex Foam Management A way forward has been determined Training then commenced with Team Leaders, Supervisors and Management.

Comments from Company Representatives

Thank you to Feltex Foam (Management, Supervisors , Team Leaders, Operators from Admin Staff to Maintenance, Logistics etc.) to make this project a success, everybody supported in their own way. The ideas brought about by Dizani  on the layout of the plant can have a great impact to Foam plant by increasing production efficiency and throughput. These are the kind of ideas that one can look forward to becoming a WCM plant.   The training has and still is a very important part of the journey in becoming WC plant. We are a long way from were one needs to be, but with constant training and daily follow-up, we will achieve great success.   Thank you for the hard work and dedication you put into this. – Zane Morgan Project Specialist