The Challenge
![](https://kaizen.com/wp-content/uploads/2022/09/process-1.jpg)
![](https://kaizen.com/wp-content/uploads/2022/09/root_cause-1.png)
Problem
• 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
![war-room-production-planning](https://kaizen.com/app/images/pt/Maintenance/mission_control.png)
![autonomous-maintenance-zero-defects](https://kaizen.com/app/images/pt/Maintenance/autonomous.png)
• 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.
![breadown-benefits](https://kaizen.com/app/images/pt/Maintenance/breakdown.png)
Breakdown
As a result of maintenance issues, breakdown times reduced by 20%
![Planned Stoppages](https://kaizen.com/app/images/pt/Maintenance/stoppage.png)
Planned Stoppages
Time for planned stoppages reduced by 26%
![Quality losses](https://kaizen.com/app/images/pt/Maintenance/quality.png)
Quality losses
Volume of quality losses reduced by 4%
![setup-time-benefits](https://kaizen.com/app/images/pt/Maintenance/setup.png)
Setup Time
Logistics productivity increase by 31% with optimization of layouts and containers
#assembly manufacturing #process manufacturing #maintenance
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