How Enduride achieved a 65% increase in sales with 20% less direct labor, while stabilizing production in a demanding operating environment.
Founded in 2005, Enduride specializes in the custom design of rollers for conveying minerals and bulk materials. The company serves key sectors such as natural resources and operates in markets across the Americas, Africa, Scandinavia, Oceania, and Europe. Recognized for its reliability and expertise, it is now a global player in its field.
In 2020, Enduride was the least profitable business unit in the M7 Group. A blame culture and low engagement were holding back any continuous improvement efforts. To turn the situation around, the plant was selected as a pilot site to implement the Toyota culture and deploy the digital Andon system.
Increase productivity without massive investments.
Reduce staff turnover to stabilize teams.
Increase the involvement of operators and the responsiveness of the position.
The Andon system is an intelligent platform that signals any interruption in real time via visual and audible alerts integrated on the shop floor. Stoppages become immediately visible, assistance is triggered quickly, and alerts are centralized to guide analysis and improve overall performance.
The project implementation was carefully planned. Each step was followed to ensure success.
Selection of the business unit as a testing ground to sustainably establish the Toyota culture.
Shop-floor support with training, daily coaching, and team incentives to drive adoption.
Installing a visual and audible digital tool to immediately signal interruptions and strengthen responsiveness.
Leveraging call logs to pinpoint recurring causes and improve process flow.
Over two years, Enduride’s turnover rate fell from 56% to 13%; production capacity per shift quadrupled, and hiring and training costs decreased.
Increased sales while reducing direct labor by 20%.
Per-shift capacity multiplied.