Process optimization in the manufacturing industry

“Understanding needs and building a solid knowledge base together always leads to positive changes in organizations.”

Lukasz Melnyk


Clear definition of goals, open mind, above all, the willingness to change at the Top Management level was the main impulse to start improving production. The project was divided into phases, in the first one it was necessary to improve flow in the process of painting wooden elements, flow analysis in the process showed a long time to go through the areas of painting preparation, painting itself and intermediate processes resulting from the technology used and necessary for the expected quality. Low utilization of the painting line and a high level of waste resulting mainly from transport and waiting at the stands have become our everyday problems to be solved.

At a glance:


  • Cost reduction
  • Improving the flow in the painting process
  • Painting line efficiency increase
  • Work ergonomics


  • Waste reduction by 30%
  • Reduction of the transition time by 20%
  • Improving the utilization of lines by 35%


Clear goals, a fixed plan, tasks assigned. Due to the close interconnection of all processes, it was necessary to start work in several places at the same time. Painting line analysis – analyzed data (60% NVA – None Value Added), measurements of transition times between processes lover 50% of the total time to go through the production) and the cycle times themselves (CT – Cycle Time) – an average of 20% to win showed that we are on the way to improvement!

Only perfect changes bring great results, and this was also the case here. The layout was changed, the positions were moved and improved at the same time related to the reduction of cycle times. The varnishing line significantly improved the disposal, new work standards were created and KPI (Key Performance Indicator) was implemented, focused on the constant support of employees by the leaders.


Benefit one

Reduction of waste in the area of painting and preparation areas by 30%.

Benefit two

Shortening the time of transition for products through the factory by 20%.

Benefit three

Improving the utilization of lines by 35%.

Benefit four

Total effect achieved without increasing employment.

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Optimization: costs, processes, Transformation
Production: stabilization of production, efficiency increase, implementation of new products
Innovations: Automation, robotization, ERP, integration, Industry 4.0
Individual projects: individually designed solutions, consulting