Shift Change Optimization
Shift Change Optimization
A simple way to improve your company's efficiency is to do the following: choose a process that is repeated every day or even several times a day, and optimize it to reduce waste in terms of time that is not value-added to the business and inefficient production starts.
Background and objectives
Customer details:
- Company dedicated to the manufacture of household chemical products
- Performance on a semi-automatic high-production line
- Analysis of the shift change process
Starting point:
- 40 minutes of end-of-shift cleaning
- 15-minute startup
- A total of 55 minutes per shift
Aim:
- Reduction of time to 30 minutes, without increasing the number of people
- A gain of 50 minutes of daily production, equivalent to an efficiency increase of 5% per shift
Calendar
Scope of work:
- Analysis – Design: plant observations
- Brownpaper & brainstorming workshop
- Design of standards and procedures
- Implementation and adjustments: on-site observations
- Implementation control: monitoring results
Analysis – On-site observations
Shift change observation (example):
Time allocation:
Design optimal observation procedure
Brainstorming & Brownpaper
FIRST VERSION OF INSTALEAN
VERSION AFTER THE WORKSHOP
Procedure design
Gantt (simplified):
Requirements and suggestions for improvement:
- 3 people trained to meet the defined standard
- Task allocation and operator balancing
- Outsourcing tasks with the machine running
- Definition of cleaning frequencies during the shift
- Recovery of units during the shift
- 5S solutions adapted to the shift change process
- Proposal for improving existing tools and utensils
- Control and monitoring of times
Standard operations sheet
Implementation and adjustments
Measuring implementation times:
Monitoring results
Monitoring implementation times:
Monitoring plant times:
Self-control by the operators
Efficiency Control line of study
Increased efficiency:
Reducing shift change time has a direct and immediate impact on line OEE:
Evolution of efficiency line of study
Increased efficiency:
