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Chemistry
Bostik, part of Arkema, is a world leader in sealing and bonding technologies and develops smart adhesive solutions for both industry and consumers. The group has 20,000 employees in 55 countries.
Bostik achieved several strong results through its improvement efforts. The factory increased total net production, improved OEE by 40%, reduced changeover time on filling machines by 70%, and reduced the need for overtime and costly weekend shifts.
The problem
Long changeovers limited capacity and drove up costs
Bostik needed to increase the total net production of adhesive while also reducing overtime and expensive weekend shifts. It was a demanding challenge.
The factory had used Good Solutions' platform for several years and knew that the collected production data was crucial for understanding production losses and finding the right improvement opportunities.
When the team analyzed the historical production data, one thing became clear. Bostik had a great opportunity to reduce changeover time. It was a particularly important source of loss because the factory changes over for around 80 different products.
The solution
Bostik found a fact-based path to faster transitions
By using Good Solutions platform as a source of facts, Bostik was able to work with reliable, real production data throughout the data-driven DMAIC improvement cycle.
The team was able to measure progress continuously throughout the project. The operators work in the platform daily, which means the team sees results in real time, can take corrective action quickly, and capture new insights that drive further improvements.
During the work, the production team saw, for example, that changeover time could be reduced even further when two operators worked together. That insight led to a new and more efficient way of working.
The result
70% shorter changeovers, more production and higher OEE
With support from Good Solutions platform, Bostik reduced changeover time on the filling machines by 70%. That improvement also increased total tonnage production at the plant.
The results were clear. Bostik increased total net production, improved OEE by 40%, reduced changeover time on the filling machines by 70%, and reduced the need for overtime work and weekend shifts.
Bostik's plant in Helsingborg now serves as inspiration for other plants within the group. The team shares the lessons learned so that more Bostik sites can achieve the same kind of results.
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