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Abstract

This master's thesis focuses on improving the production line changeover process at Schaeffler using the SMED methodology. The introductory chapters present the company and the theoretical foundations of lean manufacturing, including methods for measuring time consumption. This is followed by a detailed description of the production line and an analysis of its current state, which was conducted using activity sampling, video analysis, and spaghetti diagrams. The main part of the work consists of an evaluation of five key changeover blocks, where bottlenecks were identified, such as poor ergonomics when handling heavy effectors, lengthy robot movements to service positions, and unnecessary worker movements. Based on these findings, specific technical and organizational measures are proposed, such as modifying the program for automatic robot positioning, standardizing fasteners, or using quick-release connectors. The thesis concludes with an evaluation of the benefits of the proposed solutions in terms of cost, implementation time, and return on investment. By achieving the set goals, line downtime is minimized and its overall efficiency is increased.