Line Changeover
Project Objectives
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Minimise the time that neither line is producing and maximise the time that one or the other line is producing
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Visual management of filler stopping on one line to filler starting on the other line
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Minimise the time the line gets to rated speed
Project Team
Alex Warren
J Boag & Son
Monty Clark
J Boag & Son
Chris Whitfield
J Boag & Son
Diane Roberts
Tasmanian Bakeries
Rayne McCreadie
Direct Edge Manufacturing
Facilitators
Bob Cother
The Action Learning Institute
Les Souster
Just Lean Associates
Key measurables
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Overall Equipment Effectiveness of Line 1 & 2
Companies involved
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James Boag & Son Brewery (host)
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Tasmanian Bakeries
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Direct Edge Manufacturing
Approach taken
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Defined current process state
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Expectation of project, line capabilities, OEE target, impact on customers presented by senior managment
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Team toured operation (Line Separation caused complexities and communication barriers)
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Current Line 1 and 2 processes mapped
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Story board of initial impressions
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Stakeholder interviews
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Data collected and analysed to find ‘black hole’ in changeover time
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DMAIC and Cause/Effect used to determine root cause
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Key issues identified and action plans addressing each issue created
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Gantt chart used to plan implementation
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Regular meetings with Project Champion to monitor progress
Summary of outcomes
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Line change over average time reduced from 4 hours to 2 hours
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Better planning resulted in changeover consistency
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Ten hours of extra production time in the week
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Better standard work task completion on changeover – now tracked at Tier 1 level
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OEE improved by approx. 20% and sustained over next three months, currently running just under 80%
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Plan is now to set a two hour window for changeover