Background
A cigarette manufacturer operating 8 Hauni PROTOS 70 production lines was targeting 90% OEE (Overall Equipment Effectiveness) as a strategic goal. After 18 months of incremental improvements, they were stuck at 82% with the primary bottleneck being unplanned downtime related to spare parts failures.
Analysis
ZTLibre's engineering team conducted a 3-week audit of the facility's spare parts performance across all 8 lines. Key findings included:
- Cutting blade replacements were inconsistent — some blades lasted 3 weeks, others less than 5 days
- Garniture tape wear patterns indicated misalignment on 3 of 8 lines
- Suction tape replacement was reactive, not scheduled
- No standardized spare parts inventory system across lines
Implemented Solution
Standardized Blade Specifications
All 8 lines were fitted with ZTLibre tungsten carbide blades manufactured to consistent hardness (HRA 89-91) and geometry tolerances. This alone reduced blade-related downtime by 55%.
Predictive Replacement Schedule
Based on production volume data, ZTLibre developed a predictive replacement schedule for garniture tapes and suction tapes. The schedule was integrated into the factory's CMMS, triggering automatic reorder when inventory dropped below safety stock.
Custom Maintenance Kits
ZTLibre designed four customized maintenance kits corresponding to weekly, monthly, quarterly, and annual service intervals. Each kit contained every consumable needed for that service window, eliminating the need for separate purchase orders.
Results at 6 Months
| Metric | Baseline | After 6 Months | Improvement |
|---|---|---|---|
| OEE | 82% | 94% | +12pp |
| Unplanned downtime (h/month) | 24 | 8 | -67% |
| Annual spare parts cost | $195,000 | $142,000 | -27% |
| Inventory accuracy | 73% | 96% | +23pp |
| Order-to-delivery lead time | 21 days | 9 days | -57% |
Why This Matters
For cigarette manufacturers operating on thin margins, every percentage point of OEE improvement translates directly to bottom-line results. By taking a systematic, data-driven approach to spare parts management, this factory achieved world-class efficiency without costly capital investment in new machinery.
Partner with ZTLibre
Ready to optimize your production line efficiency? Contact our engineering team for a free spare parts audit and personalized recommendation.
