Carpentry shop: reduction of machine downtime by 3.2 hours per week
We changed the technical inspection schedule based on actual part wear. The machine stopped stalling during the largest orders.
In the Meble Gdańskie Wiśniewski plant, machines were stopping suddenly and without warning. Production stood still while workers waited for a technician. We found a way to recover 3.2 hours of machine labor every week.
The challenge
In the first quarter of 2024, the plant recorded 17 sudden breakdowns on the main production line. Each such downtime lasted an average of 43 minutes and generated losses of about 4,820 PLN per month. The inspection schedule was fixed at once a month. It didn't take into account that some machines work harder than others. Spare parts were ordered at the last minute, which extended the repair time.
Our approach
Our two-person audit team spent 9 working days directly on the production floor. We analyzed the technical logs from 14 woodworking machines, including three CNC machining centers. We measured the real wear of cutters, bearings, and drive belts in 180-hour cycles. We spoke with 12 operators to understand what warning signs were ignored before a breakdown.
The solution
We introduced a dynamic technical inspection system based on the number of hours worked, rather than a calendar date. We developed a simple checklist for operators that they fill in in 4 minutes before starting a shift. We also changed the process of managing the consumable parts warehouse. Now the system automatically reminds to order bearings when the machine approaches 165 hours of operation since the last replacement.
Results
The numbers speak for themselves. The new system eliminated most unplanned work breaks. The actual state is that the plant now completes 4 more orders per month without overtime. Savings are visible in black and white in the costs of external service.
Timeline
-
May 2024Analysis of technical logs and tool wear measurements at 14 workstations.
-
June 2024Implementation of new schedule and training for 12 machine operators.
-
July 2024Result verification and spare parts inventory optimization.
"We were skeptical because inspections every 180 hours seemed too frequent. However, it turned out that preventing breakdowns saved us 4 large contracts in July. Numbers don't lie."