BASF: Innovating technology to reduce production cycle times (Part 2)

BASF Automovite Coatings is a chemical division of the BASF group (valued at approximately $ 1.2 billion in 2004) focusing on the development and production of new paints for automotive businesses including big manufacturers as Ford, GM, Daimler Chrysler. Automovite Coatings offers a full range of thermal spray coating services to meet the requirements of the automotive market customers. The paint will provide the necessary material properties for the parts. To increase productivity, quality and efficiency, the company has implemented Kaizen events.

The company’s goal when it comes to technology innovation and the adoption of innovative tools is to reduce production cycle times when filling an order to increase overall efficiency. The initial goal is to cut this time period down to 50%. The tools and methods used are Lean, Kaizen, 5S and visual management.

Initially through a series of Kaizen events, the outlined opportunities include reducing order start times, reducing order times, improving transit, filling, and shipping processes while shortening. the distances traveled in operation. The team has identified 13 key members associated with BASF’s manufacturing process who will be trained to guide lean production. In addition, 11 people playing a role in the process were identified. A series of 36 Kaizen events was held with 174 BASF employees participating.

Lessons learned:

Time management: allowing set times to focus on improving areas, which is key for success.

• Waste treatment: the implementation of a lean management system simplifies the production process while ensuring efficiency.
• Organization: Using visual cues to help standardize work order and workspace; items are placed in easy-to-see, easy-to-find, and easy-to-find positions that shorten the waiting time.
• Evaluation: Digital technology improves data management and analysis systems, supports automatic flowchart construction and early warnings.
• Equipment performance: Regularly performed predictive maintenance increases the life of the equipment while reducing the incidence of incidents.

Thanks to its efforts in technology improvement and transformation, BASF has achieved remarkable results:

• Reduce cycle time when filling an order to 53% of original stars (equivalent to $ 74,000 / year)
• 30% reduction in product complaints on total orders (equivalent to $ 282,000 / year)
• 27% increase in efficiency of transportation, transportation and storage operations (Equivalent to $ 100,000 / year)
• Reduced shipping distance for test production from 963 feet to 327 feet (Equivalent to $ 85,000 / year)

Productivity and Quality Office