Monday, June 20, 2011

Unipak Nile One Step Closer to WCOM™ System

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Unipak Nile completes preparation and ventures into the pilot phase of Al Ghadir World Class Operations Management (WCOM™) system.


Egyptian corrugated packaging manufacturer, Unipak Nile, has launched the pilot phase of its WCOM™ system, known as ‘Al-Ghadir’. The plant began implementing Al Ghadir’s lean manufacturing principles in Q1 2011.

Al Ghadir’s three phases -preparation, pilot, and expansion- improve company performance; reduce scraps and reworks; ensure smooth process flow; zero defects and breakdowns; balance time between various operations; and manage
work in process.


Al Ghadir Pilot Phase

During Al Ghadir’s pilot phase, which will last approximately 6 months, Unipak Nile is setting up teams and training them on Total Productive Maintenance (TPM) methodology to apply on machines at the plant.

Antoine Baz, Unipak Nile Al-Ghadir Project Coordinator, states,
“To launch the pilot phase, half a day of training on methodology was spent with every team. Following the training, a large number of administrative staff joined teams on the floor and helped with the initial cleaning of the machine. The initial cleaning is intended to stretch beyond merely the cleaning aspect.”


Unipak Nile teams being briefed by Solving Efeso Consultants
 on the initial cleaning activity


One of the major activities of the pilot phase is initial cleaning. Operators tag machines prior to and following cleaning. Anomaly tags teach operators to notice problems during cleaning and to identify and differentiate problems hidden or caused by dirt.

If a problem is flagged prior to cleaning but removed after cleaning, operators deduce that the problem was a result of dirt build-up. However, if a problem persists after cleaning, then operators should find the cause of and solution to the problem.

Initial cleaning activity


The Al-ghadir methodology focuses on finding countermeasures to problems rather than relying on immediate solutions alone.  If the cause of a problem is dirt build-up updating and improving the cleaning standards would be the countermeasure to this build-up.

Initial cleaning activity
before and after


The pilot phase increases machine efficiency, consistent with Al-Ghadir’s goal to reach a smooth stream of operations with zero defects and breakdowns. Unipak Nile managers are demonstrating team support by taking part and assisting operators in tagging machines.

Elie Saad, Unipak Nile plant manager, stated,
“As an embodiment of INDEVCO value, Servant Leadership, we all went down and helped our operators tag machines.  This gave a very good impression, and the operators were amazed by this initiative.”




Unipak Nile manufactures retail ready packaging, shelf ready packaging, point-of-purchase (POP) displays, promotional cartons, and corrugated boxes for the agricultural, beverage, catering, dairy, hygiene disposables, industrial, petro/chemical, processed food, paramedical, soap and detergent industries.


Unipak Nile, located in 6th of October City, Egypt, is a member of
INDEVCO Paper Containers, a division of INDEVCO Group.

For More Information
Antoine Baz, Al-Ghadir Project Coordinator
Center for Technical Excellence
Halat, INDEVCO complex
Halat, Lebanon

Tel: +961-9-478 900 ext. 256

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