The situation
On-time shipments at 85% and changeovers averaging 45 minutes.
Scheduling and changeover performance at the Johnstown plant. The fix was sequencing discipline: combine like runs, dedicate lines, and schedule against what the field actually needed.
45 min
Average changeover on arrival
The outcome
95%
On-time delivery, up 10 points
15 min
Changeovers, down 50%
How it happened
- Built daily sequencing to combine like runs and reduce washouts and changeovers
- Dedicated lines to specific product families and situations
- Prioritized production against field inventory need
- Wash generation down 45%
- PM program redesign delivered a 16% efficiency gain
- Site set its 2013 annual output record
- Site rose from 3rd to 1st in company-wide engagement ranking in six months
- Daily sequencing
- Campaigning
- Line dedication
- PM program redesign