Maximizing Production Uptime: Tactics for Effective Changeover Reduction

A leading automotive Tier 1 supplier faced significant production challenges on their high-end automated production line. Prolonged downtime plagued the line due to lengthy model changeovers, exacerbated by an increasing frequency of these changes driven by order backlogs. This frequent disruption led to higher scrap rates as adjustments were often required during transitions. At the same time, the customer had an opportunity to grow their business based on a new program. However, they were concerned that their current capabilities would not allow them to meet the customer’s new program demand and on time delivery requirements, further compounding the pressure on their operations.

To address these issues, Hilco Performance Solutions (HPS) embarked on a phased improvement initiative focused on reducing changeover times and minimizing scrap. The project leveraged the Single Minute Exchange of Dies (SMED) methodology to identify and eliminate waste within the changeover process. A thorough analysis of the changeover process was conducted across key stations. This analysis revealed numerous wasteful activities, such as excessive operator movement and inefficient tool usage.

HPS implemented several key solutions to enhance line efficiency, including a custom-designed ergonomic changeover tool, power tools, and quick-change fixtures. These innovations reduced changeover times by 95%, from 255 minutes to just 12 minutes. Additionally, the improvements optimized space utilization and enhanced operator ergonomics. The reduced changeover times increased production flexibility, enabling the client to respond more effectively to market demands and strengthen its competitive position.

$248,000 reduction in yearly time savings

Increased Capacity to support a 45% increase in sales