SITUATION: A major sunflower oil producer contacted KWORP with a request to develop and manufacture an analogue of the mixer body from CPM Europe (Netherlands) due to a breakdown. The cost of purchasing the body from the equipment manufacturer amounted to tens of thousands of euros, the delivery time was more than 3 months, which significantly did not suit the client.

TASK: KWORP specialists were tasked with developing design documentation, manufacturing and delivering an analogue of the mixer body during a major overhaul of the sunflower oil production line within 20 calendar days.

ACTION: The body was disassembled and sent to our production facility for measurements and analysis of the reasons for the failure of the body. Then, our company’s engineers developed a complete set of technical documentation for the manufacture of the mixer body, additionally strengthening the design of the product taking into account the production capabilities and the economic feasibility of the manufacturing methods.

RESULT: A new, more reinforced mixer body (analogous to CPM Europe) was manufactured and delivered in 20 calendar days. The difference in the cost of the mixer body compared to the original body from the manufacturer CPM Europe was 5.5 times, with a reduction in the delivery time of the product by 4.5 times.

SITUATION: A European manufacturer of equipment for the dairy industry contacted KWORP with a request to update the documentation set (3D models and 2D drawings) for the installation of a curd washer after cooking, according to the technical specifications, within 20 calendar days.

TASK: KWORP specialists were given the task of updating 3D models and 2D drawings within 20 calendar days, according to ISO, DIN standards.

ACTION: Based on the customer’s technical specifications, the company’s engineers developed a set of technical documentation for the manufacture of the curd washer unit body, additionally strengthening the design of the product, taking into account the production capabilities and economic feasibility of the manufacturing methods.

RESULT: A complete set of technical documentation developed for the client was manufactured and delivered within 15 calendar days. The equipment was manufactured in the EU and delivered to the end customer.

The customer had no comments on the technical documentation during the manufacturing process. The difference in the cost of labor costs for the development of design documentation by European and Ukrainian engineers was 3.5 times, with a reduction in the time frame for completing the work by 2 times.

SITUATION/TASK: A Ukrainian manufacturer of non-standard equipment and services in the field of mechanical engineering and metallurgy approached KWORP with a request to reduce the time frame for implementing turnkey projects.

ACTION: KWORP specialists were assigned priority services based on profitability and demand variation in the company’s project portfolio. Using one of the projects as an example, VSM maps, cross-functional maps and Yamazumi diagrams of the current state and future states were built.

RESULT: SMART goals were set for the selected problems and a search for root causes (5-Why and Fishbone) was conducted, countermeasures were developed, recommendations for measuring results were developed and a list of necessary processes for standardization was determined (Solving problems using the lean manufacturing method using the A3 method).

As a result of the implementation of this project, it was possible to reduce the time frame for completing one of the key processes by 20%.