PROBLEM

This production line packaged numerous types of fruit juices requiring up to 6 changeovers per day for a total of over 35 changeovers per week.  The average changeover took approximately 35 minutes requiring a full flush and a series of lab product tests for several characteristics.  The test would sometimes fail and another clean out and flush would be performed

APPROACH

A cross-functional team was formed consisting of people from Quality, Production, Maintenance, Scheduling and Supervision.  The TIMWOODS wast assessment was conducted, and several types of wast were identified including motion, waiting and defect waste.  The SMED approach was used to identify both internal and external tasks.  Using the DMAOIC process, many internal tasks were moved to external.

SOLUTION

Numerous types of waste were identified including motion, waiting and defect waste.

Using the DMAIC process, many internal tasks were moved to external.