Product Changeover Improvements - Case StudyCable Manufacturer - NSW, Australia

A Western Sydney manufacturer of large diameter, industrial mining cables, was experiencing excessive downtime relating to product changeovers.

Baseline performance was calculated at 79% above the required target.

The time lost during changeovers equated to over 16 operational hours per day, heavily impacting the utilisation of resources and not achieving monthly production targets. 

An applied learning model was tailored to achieve the required changeover performance needs.  A project team was formed utilising the current crews and coached by an experienced Lean Six Sigma Black Belt, to implement the required change management methods.

Various customised mapping techniques were utilised to capture current state process flow and decision-making.  A SMED (Single Minute Exchange of Dyes) study was also conducted removing excessive waste from the changeover process.

The team then progressed through a series of management tollgates for approval and support, as each stage of the project was completed.  The management team removed roadblocks and assisted the project team to successfully achieve their trial plans.

The project was completed with clear and concise identification of root causes, a successful trial and clear sustainability plans to support the needs of both the process and people, delivering the required project outcome.