ALROSA’s Aikhal Mining and Processing Division has commenced the implementation of the Lean Production – also known as the Lean Manufacturing – System, popularised by Toyota and adapted by other companies in various industries.

“The lean production concept allows industrial enterprises to significantly increase labour productivity, shorten production cycle, decrease a reject rate, improve product quality, free up space, reduce inventory and extend equipment overhaul intervals,” ALROSA explained.

One of the most famous methods of this concept is considered to be the 5C system: “It helps to organise the workplace correctly, keep it clean, and maintain standards and discipline.”

Currently, work on three of the stages of the system is being carried out at the sites of the mining equipment repair shop, ALROSA said. These stages are: organising the workplace, strengthening discipline and creating safe working conditions. The entire team is involved in implementing the project.

“The launch of the project in sections No. 3 and No. 7 has already yielded quite tangible results,” commented Sergey Popovichenko, deputy chief for production at the mining equipment repair shop. “It made (it) easier to keep a workplace clean, increased its ergonomics. Working conditions have significantly improved, partially due to the strengthening of industrial safety.”

“The introduction of the 5C system has also increased labour productivity,” said Artem Polyvyanny, a team leader for the production system development at Aikhal Division. “The new approach allowed us to significantly reduce the so-called hidden losses. These are, for example, irrational movements, unnecessary logistics, demotivation of the personnel. The morale of the team improved.”

The action plan for taking lean manufacturing further is being developed by the project team; and the Company is also considering extending the experience to other sections and shops.