Reducing change over time resulted in savings of over £2M

Results: The outcome from the SMED activity has been to reduce a change- over time from 45 minutes down to 6 minutes.  This meant the change over can be accommodated in the scheduled 10 minute operator break, and has eliminated 27 hours of stoppage per year.

This equates to sustainable savings of over £2M per annum.

Background: The client is a large OEM directly involved in manufacturing.  CLS were engaged to look at significantly reducing the change over time for a process that was causing downtime and lost production.  The target was to reduce the change over time from 45 minutes to below 10 minutes so it could be carried out in a scheduled break time.  The CLS investigation found:

  • The cycle time for reclaiming gas was over 5 minutes
  • Damage was occurring to adaptors when taking them to and from the process
  • Pipes were not colour coded leading to lost time when re-engaging the adaptors
  • Tools and equipment were stored or staged in the wrong locations.

What we did: Having worked with the internal team and utilising video capture, brainstorming activities, and practical problem solving the following improvement actions took place:

  • Design and fabrication of a work table to transport the adaptors, leading to significantly reduced damage
  • Quick installation of a replacement adaptor facilitated by introducing magnetic locks instead of a screw-locking mechanisms
  • Pipe colour coding and location markings were also put in place to ensure easy recognition of the correct alignment on re-assembly
  • Tools and equipment repositioned.

Type of Business:

Sector contact for more information:
Stefan March

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