Packaging Industry
OEE & Quick Changeover Optimisation
Primary Outcome38% Changeover Reduction
Business Challenge
High-runner extrusion film lines lost 12+ hours per die changeover due to disorganized tool preparation and unstandardized procedures.
Client Situation & Operational Bottlenecks:
- •Extrusion die setup downtime averaging 12 hours per product run
- •Unorganized tool locating and missing specialized wrenches during changeovers
- •Frequent micro-stoppages and polymer trim scrap during line restarts
- •Overall Equipment Effectiveness (OEE) trapped at a low 42%
Our Approach
- Conducted video SMED (Single-Minute Exchange of Die) audit of changeover steps
- Categorized changeover tasks into internal (machine stopped) and external (machine running) elements
- Converted internal die pre-heating tasks into external prep activities
- Designed standardized color-coded tooling carts and quick-clamping fixtures
- Established visual OEE tracking boards and Autonomous Maintenance routines
Key Improvement Initiatives
- 1Rolled out standardized SMED changeover checklists and timing sheets
- 2Installed pre-heating stations for extrusion die tools next to production lines
- 3Trained machine operators and maintenance crews on parallel changeover execution
- 4Instituted 6 Big Losses downtime tracking and 5-Why root cause analysis
Before vs. After Operational Metrics
| Metric | Before Transformation | After Transformation | Quantified Impact |
|---|---|---|---|
| Extrusion Line Changeover | 12 hours | 7.4 hours | -38% |
| Overall Equipment Effectiveness (OEE) | 42% | 60% | +18% |
| Unplanned Breakdown Hours | 85 hrs/mo | 32 hrs/mo | -62% |
“
Reducing our die changeover time from 12 hours down to 7.4 hours gave us immense flexibility. Our OEE jumped 18% in just 90 days.
— VP Operations, Flexible Packaging & Extrusion Plant
KEY RESULTS
38%Changeover Time Cut
18%OEE Uplift Achieved
62%Breakdown Downtime Cut
Services Delivered
- OEE Improvement
- SMED Quick Changeover
- Total Productive Maintenance
- 5S & Visual Management
- Process Excellence
Methodologies Used
SMEDTPMOEE Improvement5SKaizen6 Big Losses
Service Capability
OEE Improvement
Maximize equipment availability, performance rate, and quality output on critical assets.
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