A global cosmetics manufacturer needed to increase plant throughput without expanding the number of lines. At the same time, the plant manager was tasked to decrease costs associated with cleaning of manufacturing equipment.
The manual washroom was particularly resource-intensive: for cleaning make-up, water-in-oil face creams, and mascara, the established process involved 9 operators standing and manually scrubbing small parts (fillers and pucks) in the sink, requiring 8 hours to return them to acceptable cleaning standards, all while consuming nearly 1922 gallons of water per cleaning. An in-house powdered laundry detergent, provided at no cost, was used.
