Moelven is an industrial group that produces building materials and systems for the construction industry; with its 52 productions units in Norway, Sweden and Denmark, it is one of the biggest in Scandinavia. This study has been carried out in the planing mill at Moelven Valåsen Wood AB in Karlskoga.
Because of the low utilization rate in the planing mill (65%), it constitutes a bottleneck, meaning it limits the capacity and flow of material, for most of the products. The purpose of the study was to analyze the stoppage in the planing mill in order to make recommendations on how the utilization rate can be increased.
The study began with a wide perspective to identify the reasons behind this problem. A summary of all stops in the planing mill concluded that set ups of the planer made up for 30% of total stoppage. Because of this, the study was narrowed down to mainly analyze the different types of set ups, which was done through extensive observations and videotaping. The solutions and recommendations that were given are therefore almost entirely regarding set up-time reduction, and more specifically, milling set ups. The recommendations, based on the results of the study, includes:
• Suggestions on how to separate internal and external set up.
• Better order of tools through designing a check table.
• Standardizing the procedure by creating a routine and dividing the operators into different work roles.
• Involving everyone in the organization in order to work with continuous improvement.
A simulation of milling set ups was done by implementing parts of the recommendations – this resulted in a setup up-time reduction of 13 minutes, which corresponds to 32.5%. Because of common denominators, such as movements, the recommendations given are likely generalizable for all set ups.