Century Yuasa Batteries – Quick Change Overs

Century Yuasa Batteries – Quick Change Overs


  • 5S
  • Problem Solving
  • 8 Wastes
  • Value Stream Mapping


Century Yuasa Batteries are one of the world’s largest manufacturers of lead acid car batteries. The Australian plant, located in Brisbane, has been long challenged with reducing change over times. The task of reducing change over time on the main production line was tasked to the frontline leaders and operators.

Efficiency Works were engaged to:

  • Expose the Operations team to a suite of Lean Six Sigma methodologies such as structured problem solving, root cause analysis, 5S, Value Stream Mapping, and 8 Wastes.
  • Establish a quick changeover methodology for all production lines. 

These objectives were successfully achieved through:

Certified Training: All Team Leaders and Supervisory staff took part in a ten-unit certificate of Competitive Systems and Practices course.


  • Introduction and practical application of Lean Six Sigma tools.
  • Establishment of an end-to-end change over reduction time procedures
  • Immediate results through practical application of theory to the workplace
    • Change over time reduced by 20 minutes.
    • Productivity increased by 10%.
  • Galvanized the leadership team and overcome silo thinking.
  • Enhanced engagement, trust, and participation throughout the organisation.