We can only achieve common quality goals and excellence if we all have the same level of understanding – from the production process to quality testing. Precisely this is the core element of the project with an important CleanFlex® clean room packaging customer: instead of classic audits, mutual visits to each other's clean rooms took place.

The team consisting of Marie-Theres Spreckelmeyer (lean management plant 1), project manager Matthias Keller, Robert Leipi (CleanFlex conversion special foreman), and project manager Pascal Altesellmeier is thrilled: "That aroused a proactive approach. We've never had so many suggestions from the production team before!"

The center of interest was a double bag with a sealed adapter ring. The customer completes the bag with a connector. The bag is required for working in the isolator or "glove box", for example, to refill syringe stoppers for filling vaccine doses.

The initiative was launched in November 2024 with a visit by managerial staff, the sales department, and the quality assurance department to the customer in France. "We wanted to talk about it and see for ourselves which standard we are pursuing in the clean room – and how we can achieve it," state the team. A further visit took place in May; this time, employees from every shift took part. 

Focus was on modern inspection methods. While ring light magnifiers were previously used for inspection, both parties now rely on illuminated tables. "We were able to convince ourselves on site that you can see more and more clearly with them," reports Pascal Altesellmeier.

The three-day training course encompassed theory and practice – from presentations to work on the production line. Language barriers were overcome with the support of colleagues.

The result was specific measures in Lengerich, revised training content, and extended equipment. A pleasing side effect is even more team spirit and proactivity. "The visit to France gave us a real boost. A lot of ideas were tried out immediately during the shift," says Robert Leipi.

Openness within the team has also increased: "Sometimes, a sample with a Post-it is lying on my desk in the morning: Might we be able to do it like this too?," says Marie Spreckelmeyer. A fault catalog with appropriate samples was also added, something that is particularly helpful for new colleagues.

The double bag with ring closure project was successfully completed in the summer. Open dialogue and committed cooperation have enabled us to specifically and sustainably take product quality to a new level – precisely according to our customer's requirements.

This project impressively demonstrates just how powerful active cooperation can be. A success story! The next project of this kind is already in the wings.

#proactive approach #active learning culture #excellence #responsibility