Bostik increased total tonnage output by improving OEE 40% using RS Production

“We did a data-driven DMAIC Six Sigma improvement cycle. We could deliver a 70% changeover time reduction by using high-quality production data from RS Production. We have maintained our improved changeover time by continuously measuring and triggering digital checklists based on production events using RS Production.”

Claes Lindblom, Six Sigma Greenbelt and Production planner at Bostik Helsingborg

Bostik, an Arkema company, is a world-class leader in sealing and bonding technologies, producing smart adhesive solutions for industries and consumers. The group employs 20 000 people in 55 countries.

        Key results using RS Production for Bostik:

        • Increased total tonnage output.
        • Improved OEE by 40%.
        • Reduced filling machine changeover time by 70%.
        • Minimized overtime work and weekend shifts.
                Claes Lindblom, Six Sigma Greenbelt and Production planner at Bostik Helsingborg

                Problem

                Bostik needed to increase the total tonnage output of adhesive and reduce overtime work and expensive weekend shifts. A tough challenge for sure.

                Bostik has used RS Production for several years. The team understood that the collected data is vital to comprehend production losses and find improvement opportunities.

                The historical data gave a clear clue. Bostik had an opportunity to reduce changeover time. A key loss reason since the factory does production line changeovers for around 80 different products.

                            Bostik needed to increase the total tonnage output of adhesive and reduce overtime work and expensive weekend shifts.

                            Solution

                            Using RS Production as a fact source, Bostik could work based on reliable, real-life production data throughout the data-driven DMAIC improvement cycle.

                            Progress could be measured easily throughout the project. Operators work day-to-day with RS Production, which means that results could be seen in real-time, corrective actions could be taken quickly, and further learnings and improvements could be made.

                            For example, the production team realized that resetting time could be further reduced by two operators working together. This learning introduced a new way of working.

                                            Operators work day-to-day with RS Production.

                                            Results

                                            Bostik reduced filling machine resetting time by 70% using RS Production. The resetting time reduction resulted in an increase of total tonnage output for the factory.

                                            Key results for Bostik:

                                            • Increased total tonnage output.
                                            • Improved OEE by 40%.
                                            • Reduced filling machine changeover time by 70%.
                                            • Minimized overtime work and weekend shifts.

                                            Bostik’s factory in Helsingborg now serves as inspiration for others. The learnings are being shared throughout the group’s factories to enable more Bostik sites to realize the same results.

                                                                    Claes Lindblom explains how Bostik increased total tonnage output by improving OEE by 40% using RS Production.