Purpose
Changeover time reduction, definition of procedures and teamwork organization during the changeover process.
One of the leading companies in the modern heating systems industry – specialized in the production of instantaneous water heaters, DWH cylinders, heat pumps and electric boilers. The company has over 30 years of experience and is recognized for its innovation, high product quality, and commitment to customer satisfaction. It operates four technologically advanced production facilities and is dynamically expanding its sales in international markets.
Project Challenges
- Lack of standardized procedures for changeover operations
- Lack of awareness that changeover time is non-productive time
- Absence of a designated line leader on the production line
- No information available regarding material availability status for the next product
- No freezing of the production schedule prior to changeover
- No planning of changeover duration
- Poorly designed production line layout (no possibility to initiate changeover without fully clearing workstations of materials from the previous product)
Implemented Solutions
- SOP – standard operation procedure for the changeover team
- Definition of communication signals triggering changeover activities
- Reconfiguration of the production line to enable the launch of the next product without the need to clear the line
- Monitoring of changeover times and continuous improvement based on collected data
- Freezing of the production schedule and advance planning of changeovers
Tools Employed
- Basic Lean Management training
- SMED (Single-Minute Exchange of Die)
- Work standardization
- Communication
- Planning