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Optimising Changeover through Lean-Manufacturing Principles: A Case Study in a Food Factory

Author

Listed:
  • Guillermo Garcia-Garcia

    (Centre ‘Camino de Purchil’, Department of Agrifood System Economics, Institute of Agricultural and Fisheries Research and Training (IFAPA), P.O. Box 2027, 18080 Granada, Spain
    Department of Chemical and Biological Engineering, Sir Robert Hadfield Building, The University of Sheffield, Sheffield S1 3JD, UK)

  • Yadvinder Singh

    (National Centre for Food Manufacturing, Holbeach Campus, The University of Lincoln, Park Road, Holbeach PE12 7PT, UK)

  • Sandeep Jagtap

    (Sustainable Manufacturing Systems Centre, School of Aerospace, Transport and Manufacturing, Cranfield University, Building 50, Cranfield MK43 0AL, UK)

Abstract

Operations management is a key aspect in any manufacturing business. Optimising the management of manufacturing operations allows improvement of the productivity and efficiency of industrial activities. To achieve this, reducing waste from manufacturing processes and, therefore, implementing lean-manufacturing principles, is key. This article presents a case study to reduce waste in changeover processes at a ready-meal manufacturer based in South Yorkshire, UK. We identified a large number of activities as part of the changeover process. We applied the Single Minute Exchange of Dies (SMED) methodology to reduce and, whenever possible, eliminate changeover, and line hopping to further optimise changeover. After implementing improvement measures, changeover time was reduced by nearly 30%, OEE was increased to over 70%, and labour costs were reduced by 10%. This shows how lean principles can aid in implementing more effective and economically sustainable manufacturing operations.

Suggested Citation

  • Guillermo Garcia-Garcia & Yadvinder Singh & Sandeep Jagtap, 2022. "Optimising Changeover through Lean-Manufacturing Principles: A Case Study in a Food Factory," Sustainability, MDPI, vol. 14(14), pages 1-20, July.
    • Handle: RePEc:gam:jsusta:v:14:y:2022:i:14:p:8279-:d:857067
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    References listed on IDEAS

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    1. José Roberto Díaz-Reza & Jorge Luis García-Alcaraz & Valeria Martínez-Loya & Julio Blanco-Fernández & Emilio Jiménez-Macías & Liliana Avelar-Sosa, 2016. "The Effect of SMED on Benefits Gained in Maquiladora Industry," Sustainability, MDPI, vol. 8(12), pages 1-18, November.
    2. Guillermo Garcia-Garcia & Guy Coulthard & Sandeep Jagtap & Mohamed Afy-Shararah & John Patsavellas & Konstantinos Salonitis, 2021. "Business Process Re-Engineering to Digitalise Quality Control Checks for Reducing Physical Waste and Resource Use in a Food Company," Sustainability, MDPI, vol. 13(22), pages 1-14, November.
    3. Ciavotta, Michele & Detti, Paolo & Meloni, Carlo & Pranzo, Marco, 2008. "A bi-objective coordination setup problem in a two-stage production system," European Journal of Operational Research, Elsevier, vol. 189(3), pages 734-745, September.
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    Cited by:

    1. Aroub Alnasser & Nsreen Musallat, 2022. "Food Sustainability Knowledge among Saudis: Towards the Goals of Saudi Vision 2030," Sustainability, MDPI, vol. 14(18), pages 1-17, September.
    2. Yildiz Kose & Hatice Nida Civan & Ertugrul Ayyildiz & Emre Cevikcan, 2022. "An Interval Valued Pythagorean Fuzzy AHP–TOPSIS Integrated Model for Ergonomic Assessment of Setup Process under SMED," Sustainability, MDPI, vol. 14(21), pages 1-30, October.

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