Three DP World teams have been recognized with global Kaizen awards for achievements in operational excellence (OPEX) and innovation. The teams are based in the Americas and have been recognized for success in continuous improvement, customer value and safety.
The Global Kaizen Awards celebrate teams that exemplify Kaizen, the philosophy of making small, smart changes that lead to meaningful impact.
“These award-winning projects show the power of empowering teams to innovate,” said DP World. “From sustainability gains in Middletown, to space and productivity optimization in El Paso, to port process enhancements in Santos – each project demonstrates how Kaizen delivers measurable value to DP World’s customers, people and our planet.”
DP World Americas teams win Kaizen awards
The three teams are Middletown, Pennsylvania, US, El Paso, Texas, US and Santos, Brazil.
Middletown, Pennsylvania
- Category: Contract logistics
- Focus: Sustainable strategy to reduce plastic/cardboard waste and boost efficiency through innovative technology.
The Middletown team tackled underutilization of its Packsize X4 machine and outdated packaging processes, leading to excess waste and lower efficiency. By redesigning workflows, consolidating pick and pack operations, and fully enabling right-size box production, the team delivered:
- 34 reduction in cycle time.
- 54 percent increase in units per hour (UPH).
- 26 percent improvement in machine utilization
- 30 percent increase in volume handled.
- 74 percent reduction in cardboard usage.
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El Paso, Texas
- Category: Contract logistics
- Focus: Improving put-away and pick performance through 5S and layout optimization.
The El Paso II Auto team identified that three key parts caused 88 percent of relocation-related inefficiencies. Using slotting analysis, Lean principles, 5S and Failure Mode and Effect Analysis (FMEA), they repositioned frequently used materials into a “golden zone” and optimized warehouse layout. The results included:
- 36 percent increase in bulk capacity.
- 10 percent improvement in space utilization
- 19 percent reduction in cycle time.
- 66 percent reduction in replenishment time.
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Santos, Brazil
- Category: Ports and terminals.
- Focus: Increasing gate productivity through a dedicated empty chassis process.
The Santos team streamlined the Gate IN process by creating fast lanes for empty chassis, bypassing the OCR portal, eliminating unnecessary inspections and deploying handheld devices with targeted staff training. Outcomes included:
- Transaction times under one minute for empty vehicles.
- Transaction times under two minutes 30 seconds for trucks with containers.
- Increased monthly truck processing capacity.
- Annual cost savings.
- Enhanced operational safety, resource efficiency, driver satisfaction and environmental performance.