Benchmarks & Client Cases

Production Efficiency in Process Industry


The Challenge


• Breakdown Maintenance losses of 14.7 hours/month

• Total duration of planned stoppages over the course of one year was 168.1 hours

• Average setup time of 74 min

• Quality losses of 9.15%

Root Causes

• Lack of information on unplanned stoppages and ad-hoc resolution of problems

• Performance losses due to lack of standard parameters for production

• Inefficient planned stoppages due to poor diagnosis, lack of resource allocation, material preparation and team coordination

• Micro-stoppages in paper transformation and undefined setup activities

• Suboptimal planning sequences

The Solution


• Structured Problem-Solving approach for unplanned stoppages, supported by detailed data

• Definition of optimal production parameters

• Standardized procedures and operators training

• More frequent planned stoppages managed through project management tools such as Last Planner, Risk Analysis and Task Kanban

Autonomous maintenance to reduce micro-stoppages during paper transformation

• Production sequencing guidelines and process standardization to minimize setup activities

The Results

The project had a payback period of 4 months with annual savings surpassing £1,7 million.



As a result of maintenance issues, breakdown times reduced by 20%

Planned Stoppages

Planned Stoppages

Time for planned stoppages reduced by 26%

Quality losses

Quality losses

Volume of quality losses reduced by 4%


Setup Time

Logistics productivity increase by 31% with optimization of layouts and containers

#assembly manufacturing #process manufacturing #maintenance

See more on Process Manufacturing

Find out more about transformation in this sector

See more on Operations

Find out more about improving this business area

Get the latest news about Kaizen Institute