Situation
A global manufacturing organization faced challenges in industrializing its production processes, particularly when collaborating with machine and equipment suppliers. These large-scale projects required careful planning, effective resource allocation, and seamless execution to ensure timely and efficient production launches.
Key issues included:
- Inadequate machine availability impacting uptime.
- Lengthy setup times and inefficient changeovers.
- Challenges in aligning supplier efforts with lean manufacturing principles.
The company sought to optimize its collaboration processes with suppliers to improve efficiency and mitigate risks during industrialization.
Task
The primary objectives were:
- Define Key Performance Indicators (KPIs): Establish measurable goals for machine availability, setup times, and changeover efficiency.
- Plan Special Processes for Assembly Lines: Develop bypass options and quick changeover procedures to ensure flexibility and continuity.
- Incorporate Lean Principles: Align project requirements with lean manufacturing criteria to reduce waste and improve ergonomics.
- Streamline Resource Allocation: Ensure adequate supplier staffing, particularly skilled PLC programmers, during the installation phase.
- Validate Performance with Testing: Conduct rigorous Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) to meet operational benchmarks.
Action
To address these challenges, a structured approach was implemented:
- KPI Development: Collaborated with stakeholders to define clear KPIs for machine performance, setup times, and productivity.
- Assembly Line Flexibility: Designed bypass systems and backup options to maintain production during equipment downtime.
- Lean Integration: Conducted simulations of U-shape and I-shape layouts, optimizing workflow and ergonomics for increased efficiency.
- Resource Planning: Coordinated with suppliers to allocate skilled personnel for commissioning, ensuring no delays during critical phases.
- Comprehensive Testing: Ensured sufficient try-out parts for FAT and SAT and conducted capacity testing to validate system readiness under real-world conditions.
- Administrative Simplification: Created shared workflows and transparent status tracking systems to minimize administrative burdens and keep project teams focused.
Results
The project achieved the following outcomes:
- Enhanced Machine Uptime: Optimized resource planning and bypass strategies reduced unplanned downtime.
- Improved Efficiency: Quick changeover procedures minimized setup times and increased productivity.
- Lean Manufacturing Alignment: Optimized layouts and workflows improved operational efficiency and reduced waste.
- Successful Commissioning: Comprehensive testing ensured equipment met all performance requirements, supporting a smooth production launch.
- Streamlined Collaboration: Simplified workflows and transparent status tracking improved coordination between the organization and suppliers.
Conclusion
This industrialization project highlights the importance of defining clear KPIs, planning for flexibility, and leveraging lean principles to ensure success when working with machine and equipment suppliers. By adopting a structured approach, the manufacturing organization achieved a seamless production launch, setting a benchmark for future projects. For more insights into managing industrialization projects, contact Lighthouse Consultings at addvalue@lighthouseconsultings.com.
