Reducing changeover time by 50% at a cosmetics manufacturer
The growth of an international cosmetics manufacturer should be
supported by increasing production efficiency and reducing unit
costs. An annual output of about
30 million units was
characterized by its diverse range of packaging and products and
requires numerous set-up and changeover processes. The aim of the
T.A. Cook analysis was to raise the overall equipment efficiency
(OEE) of the production lines from 60% to 75% and to reduce
unproductive downtime with the following results:
Increase of OEE as a result of changeover time reduction
Optimized production and capacity planning
Increased motivation of workers
Approach
T.A. Cook analyzed the OEE-performance killer and evaluated the OEE
target values at two selected filling lines. Potential opportunities
to reduce unit costs, increase process efficiency and enhance OEE
were to be identified and defined.
During the review of
the production process, particular attention was paid to recording,
categorizing, evaluating problems and responses to the changeover
process, switching from one product to another, as well as
cooperation between the changeover and set-up teams.
T.A.
Cook evaluated the entire operative planning, execution and
controlling processes in production, including all interfaces, roles
and responsibilities and accompanied workers on-site to chart and
assess the activities of the assembly line and maintenance staff
during different shifts. Benchmarks were determined for each shift,
best-practices were compared and a critical path for the changeover
was identified.
Achievements
The analysis showed the client what areas needed to be tackled and
how much potential existed to quickly improve the changeover process
and increase the effectiveness of the plant. Examples include
remodeling the changeover process, optimizing non-productive times
such as cleaning and staff breaks, undertaking technical
improvements or integrating maintenance into the remodeling process.
The improvement potential was determined as 50%, which would result
in an
increase of 10% in OEE.
The related optimization of costs
would, as intended, support company growth and ensure a measurable
and long-term competitive advantage.