Lean Manufacturing

LEAN MANUFACTURING SYSTEM

OZNA seeks to increase the efficiency of business and optimize project delivery time. To this end, a lean manufacturing system is being implemented at the manufacturing sites:

  • the manufacturing is aligned towards creating value, and the value stream is visualized to reduce the product assembly cycle
  • the value stream includes only those components and units that help to create value
  • all manufacturing sites are divided into separate zones and clearly marked
  • supply zones contain a ready stock of frequently used materials, OZNA-made parts and components that will be involved in the process of creating value within the forthcoming 24-hour period
  • every manufacturing zone is designated for a certain type of operations and contains no objects irrelevant to the manufacturing
  • the use of overhead cranes is limited to moving materials and purchased integrated parts, installing such parts, and moving process units
  • a cross-docking system is in place to facilitate the delivery of parts closer to the manufacturing sites, thus increasing the speed of logistical operations
LEAN MANUFACTURING SYSTEM
IMPROVEMENT PROJECTS

Over the past year, the implemented lean manufacturing has already helped to nearly halve the assembly cycle of metering units to the current 25 days. In fact, the system of continuous improvement allows our assembly lines to manufacture more than 200 process units a month.


Over the past 3 years, we have completed a number of optimization projects, both small and large. By arranging the value streams of our core products and building cross docks we have significantly reduced such wastes as idle time and unnecessary handling operations. Our “lean project” sites have shown a 1.5–2 fold increase in manufacturing speed.


Effective 2019, the Company management has focused on office workflows in addition to manufacturing. The Holding divisions JSC OZNA-Metering Systems and LLC NPP OZNA-Engineering are participating in the national program of Labour Productivity and Employment Support.

IMPROVEMENT PROJECTS
PRODUCTION FACILITIES UPGRADE

Our organizational changes are consistently supported by investments in state of the art manufacturing technologies. In 2017, OZNA launched a new process of protective coating application involving shot blasting and powder painting. This helped us to enhance product quality with a substantial improvement of operational characteristics of the equipment being manufactured for corrosive environments and challenging conditions where the cost of equipment ownership tends to become top priority for the Client.

PRODUCTION FACILITIES UPGRADE
HIGH STANDARDS OF QUALITY AND OCCUPATIONAL SAFETY

OZNA pays a lot of attention to occupational safety and eco-friendliness of the manufacturing process. We have been revising our system of internal audit and splitting the manufacturing cycle into “clean” and “dirty” sites whereby the processes of welding, painting, assembly and mechanical treatment are carried out in isolation from each other. This will help to promote a higher culture of assembly work and ensure safety of mechanical and stockpiling processes.

Our product quality conforms to international standards and has earned international and Customs Union certificates. The company quality management system is certified as per ISO 9001:2015 and also complies with the industry standards of SDS-Gascert and SDS-Transcert.

HIGH STANDARDS OF QUALITY AND OCCUPATIONAL SAFETY

up