Dovista Poland Sp. o.o.
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The eight plants in Dovista Polska’s Window Village make custom-order windows and doors that are exported to homes and commercial buildings in the United Kingdom, Germany, Denmark, and other Scandinavian countries. The Dovista Window Village site leaders started the improvement initiative in the T4 factory because productivity was languishing at 60% of the engineering standard.
Following the two-week diagnostic and management’s approval of the improvement plan, TBM’s European team began working with the T4 production teams at the end of February 2020. This was weeks before most European countries mandated economic lockdowns to control COVID-19 outbreaks. Although the gates were closed to nonessential contractors, company leaders gave special permission for TBM to enter because this project was a strategic business priority.
The production lines in Dovista’s modern, well-lit facilities are highly flexible and engineered to manufacture many different-sized windows and doors, all of which are made-to-order.
We identified improvement opportunities during the diagnostic, which included scheduling inefficiencies, time spent moving around work-in-process trollies to find the right parts, and a variety of other issues that were impeding workflow and undermining productivity. Some workers were overburdened and rushing to get their work done while others were standing around waiting.
Our initial priorities included:
TBM’s engagement with Dovista began in January 2020, gathered momentum during European lockdowns, and continues to expand.
The approach and progress in T4 has served as model for rollouts in other facilities in Window Village. Adherence to the rolling takt time on the T4 paint line reduced cycle times by 18% and improved daily productivity of windows and doors per day by 12%.
Other floor-level results include:
At a Glance
Client
Results
