Improving Efficiency in Complex Manufacturing Processes Using SMED. The Coca-Cola HBC Italy Case

This thesis addresses the optimisation of the changeover process in the can production line of Coca-Cola HBC Italy. The issue arises from the increasing necessity for multinational corporations to offer highly customised products that reflect the evolving needs of consumers. In the current globalised market, where competition extends worldwide, it is imperative for multinational enterprises to remain aligned with market trends, even when this entails a significant increase in the complexity of industrial processes. For Coca-Cola HBC Italy, this requirement translates into the production of a wide range of product formats, which inevitably demands frequent changeovers. Consequently, the optimisation of changeover operations represents a strategic priority for the company. The study has been conducted through the application of Lean Manufacturing principles, with reference to the Single Minute Exchange of Dies (SMED) methodology. To ensure methodological rigour, the research has been structured in accordance with the DMAIC framework. The results obtained are of considerable relevance. Ramp-up times were reduced by 55.7%, thereby achieving a substantial improvement in efficiency. This outcome is particularly noteworthy as it concerns the reduction of a non-value-added activity, namely post-changeover adjustments, obtained with a limited investment of resources (one dedicated operator, 8 hours/day for 5 months). In addition to the reduction in ramp-up time, the implementation of the project led to a decrease in the overall duration of changeover operations. However, the most significant result lies in the strong engagement of line operators, whose active participation proved to be a decisive factor in ensuring the sustainability of the improvements over time.