New production line and LEAN are a complete success for Sulzer in Kotka

Sulzer Pumps Finland Oy, which has been operating in Kotka for two centuries, employs around 500 people in Finland. The factory manufactures top-quality pumps, mixers, compressors and aeration equipment for processes in various industrial sectors. The energy crisis and global logistical problems of recent years have also affected the Karhula pump factory. Overcoming the challenges has required extensive measures.

In response to a global component shortage, Sulzer in Kotka made two major changes to ensure operations. The production of process pumps was centralized on a new production line in Karhula, Kotka, which was completed last year. In addition, a LEAN operating model was introduced to manage daily work.

“Centralizing operations in Karhula helped as the first means of survival. The centralization of several production functions, assembly and storage was aimed at, among other things, logistical advantages and improving operational efficiency. In addition, the new production line was used to increase production efficiency. In addition to production economics reasons, the decisions were also influenced by the factory’s long history. The Karhula pump factory has always been a significant location for Sulzer,” says the production manager at the Karhula factory. Kalle Leaf. 

“The effects of the component shortage are still visible, but at the same time we have made great strides forward, as the new production line has significantly increased our capacity. Both delivery times and the ability to meet customer needs have improved.” 

To support the changes in the factory's physical environment, Karhula implemented the LEAN management model. This is a business philosophy that aims to continuously improve productivity, optimize resource use, and eliminate waste without forgetting people.

“LEAN management practices have had a huge impact on the daily operations of the pump factory. With increased efficiency and the elimination of unnecessary work steps, it has also been possible to reform the roles of employees. People now have more responsibility and power to influence their own actions. The meaning of work and participation are increasing, increasing well-being at work,” says the new CEO of Sulzer Pumps Finland Oy. Marja-Leena Mäkinen.  

Of Sulzer's many factories, the Karhula factory was the first to implement the LEAN management model on such a large scale. As a result of the reforms, the Karhula factory achieved the company's best result in Finland in the spring of 2023. Thanks to the good results observed in many different indicators, the new operating model is planned to be implemented globally in other factories in the group.