Optimization of Changeovers : The process of optimizing changeovers with Lean Production tools

Abstract: The production line at Mondelez International is heavily exposed to changeovers and is not originally designed to manage the vast amount- and frequency of the occurring changeovers. The aim is thus to decrease the total changeover time on the production line by applying several methods such as SMED and by reducing any wastes related to the changeover. The goal was furthermore to introduce the concept of Industry 4.0 to the company as a philosophy that will lead to automatic information gathering and correct performance analysis. These implementations, ideas, and key concepts could later on be implemented in other production lines in the factory both locally in the plant, but also globally in other factories. The methods used to reduce the changeover time were based on random timings taken from the production line combined with interviews with operators and experts within respective fields. In order to optimize the problem areas that were found in the production line, it was necessary to find several solutions to each problem, as each solution had its own benefits. These solutions were then analyzed and compared to each other in order to find the best possible solution for each case. The results of the project are that the total yearly changeover time of the production line could be reduced by a significant amount of time and this would reduce the costs of running the production line. Industry 4.0 can be applied to the production line by adding sensors to some machines on the production line. These sensors will then report when the production line is undergoing a changeover and the information is stored in a database which can either automatically or manually be analyzed in order to find out where the main problems are occurring in the production line. This would decrease the time it takes in finding out where the problems are, and would also over all help in keeping track of the state of the production line in a more detailed and controlled way as compared to the current fully manual database system.