The last 2 years for the factory Fläkt Bovent in Ołtarzew meant constant development and launch of new production lines such as VAV regulators and Fire Dampers. Simultaneously the expansion of the plant by another valuable square meter was impossible in the current location. Furthermore, product lines moved from our other factories were equipped with different colour machines, often not modern despite their mechanical efficiency. New technology lines were located in areas previously used for storage. It made an atmosphere of temporariness which didn't work well for the Group's standards in the factory.
Therefore, a serious challenge had to be addressed:
How to fit all technological lines in the warehouse with limited space, reaching the standards of a modern factory whilst still maintaining production continuity?
For this purpose it was necessary to define the most important changes:
Optimization and layout changes to production processes
Adaptation of the machines and work areas to the latest EHS standards
Gaining additional space to enable the factory to grow
Make changes with continued production without delays in delivery
To optimize production we needed to implement LEAN standards and ISO standards with procedures and documentation for each process. We received our ISO certification in Q3 of last year. Now, we are able to grow more efficiently and it is much easier to train new employees. We have also identified several processes, which are not significant for the main production, but time and area-consuming. We decided to outsource them. Also part of the warehouse is external, this provides greater flexibility and enables us to focus on main production tasks.
Introducing the latest EHS standards including floor-painted production areas, safety zones and communication lines needed the whole space to be rearranged. Newly located zones have forced the renovation of the machines. The employees were involved in painting smaller machines and all machines were upgraded to the latest safety requirements. New safe, clean and spacious workplaces are more employee-friendly which means everyone takes more pride in caring for tools they have renewed. These changes improved safety and production efficiency of the factory. By making layout changes we saved 200m2 of valuable space which can be utilized for future development and saved floor space has made possible the Concern Room construction for effective stand-up meetings. We have seen increased motivation from employees which is an excellent result!
The true success has been achieved in building a motivated team who have felt involved in the whole process, everyone had done their best to accomplish all goals without stopping production.
One of the most striking factory renovations was realized in our manufacturing facility in Turkey. Factory-wide renovations continue to be carried out at every stage with the contributions from employees at all levels.
To be an effective producer in today's international competitive world, you need a modern, well-organized production facility that manufactures products that add value to our customers in the most efficient way. With this understanding, our Turkey factory was completely renewed. Due to the fact that the factory floor is small, more innovative solutions were developed.
The entrance of the factory has a new look. An extremely modern security room and concern room was built. In addition to all these, ‘5S’ application was applied to all the factory working environments. The aim was to optimize working conditions in terms of performance, comfort, safety and cleanliness. It also provides a clean and organized work environment and reduces wastage and variability.
"The main purpose of the transformation was to increase productivity in the factory. In this respect, we have increased our production speed and provided an environment where employees can work more regularly, comfortably and safely. We will be able to create value for our customers in a higher quality environment in the coming days. Although the factory area is not very large, the line manufacturing method applied since 2013 has been renewed as part of the order. At this point, production capacities increased by 75%." says DencoHappel Turkey Plant Manager Gökçe Funda.
The transformation of the Istanbul factory required a holistic process to be applied to all areas, large and small. The main goal is to minimize unnecessary waste time, to create a safer and more efficient working environment, to prevent waste, to optimize the recycling and use of materials.
Our facility in Turkey has been transformed and completely renovated to be a more efficient, and better quality producer.
Thanks to this process:
The working methods of employees in all lines were generally observed
The materials needed in each line were rearranged in such a way that they could be reached most easily and in a certain order
All used equipment is labelled and placed in a wheeled, easy-to-carry and easy-to-carry cabinet
A significant change took place in the entrance section. This section has been completely renewed and has a new look. An animated film was drawn for the visitors, drawing attention to the in-factory work safety rules. It is possible to see all the work safety materials used in this section where every detail is considered for factory visitors. All employees were trained on the necessary work safety equipment and were allowed to use these materials continuously.
In addition to all these, the outside spaces where the workers can relax in their spare time and enjoy their time can be renewed and regulated.
In order to manage increasing sales orders we had to accelerate the commissioning and installation of the automated panel assembly line and create higher capacity in the final assembly.
The space in the exisiting layout was almost fully occupied and we needed to create additional areas to install a new line
Additional space has been created in an external warehouse by arranging the stored material on racks whilst also reducing the inventory.
Around 500 sqm. has been saved in the main production hall and a new assembly line is operational as of September.
The new line is bringing an additional €1 Million sales capacity per month which represents a 10 % increment on the same floor.
Thanks to this process:
We will be able to improve the time to deliver
Meet the requirments of ever-changing market demands & order volumes
Have a dedicated line for specific product ranges and enable the new platform for FRESH launch