Premium gift box rapid changeover (SMED) lean project: changeover time cut from 26 to 10.4 minutes, saving an estimated RMB 51,000. RCG coached this Hong Kong-listed printing company on-site in lean production.
Project results: from the initial 26 minutes down to 10.4 minutes; estimated savings: RMB 51,000
Project background:
Against a backdrop of a worsening external economy and falling profits, the group issued a directive that the company must cut costs internally and implement lean production to eliminate waste, so a project team was set up for the premium gift box workshop.
Current state:
Data collection showed that the main issues affecting efficiency in the premium gift box workshop are:
Changeover time accounts for the largest share, so rapid changeover was chosen as the core improvement focus
Target setting:
Data collection showed an average changeover time of 26 minutes per changeover, affecting 22 people
The target was set at 15 minutes, with a project period of 4 months
1. Data collection showed that Type B changeovers take the longest and occur most often, so Type B changeovers were chosen for observation.
2. Video recording and motion analysis were used to identify improvement points.
3. Countermeasures for the improvement points were developed and implemented.
4. Standardized output.
