Using Lean Methodology to Reduce Changeover Time in Packing Line

Abstract

Abstract - One of the metrics to measure efficiency in packing lines is Process Reliability (PR). It has been identified that the PR loss in packing Line X due to changeovers is 16%. The objective of this project is to use lean methodology to reduce the changeover time of Line X from 77 to 57 minutes during a three month time frame. This represents a 25% changeover time reduction obtaining savings of forty thousand dollars a month. Work Process Improvement tools were used in conjunction with the DMAIC approach to achieve an average changeover time of 46 minutes exceeding our initial objective. The data gathered from the change over critiques show that the improvement has been consistent and more than 80% of the changeovers are being completed on the new 46 minutes target, confirming that the use of the company’s Work Process Improvement tools proved to be very efficient. Key Terms – DMAIC, Machine Changeover, Six Sigma Tools, SMED