Manufacturer Increases Efficiency, Grows Revenue

We identified a number of problems, including the plant’s disconnected floor plan layout. As a result, moving materials from one station to another involved a lot of unnecessary travel. Also, fabrication areas were not connected to the main line, and assembly line workers had to constantly retrieve parts. This slowed production considerably. The entire process needed to be better choreographed to function more efficiently.

To determine the true capacity and capabilities of each work cell, our team quantified the waste in the existing processes and calculated the potential for increased output. Using direct, on-the-floor observations and applying Lean Manufacturing principles, we were able to eliminate redundancies to produce more products more quickly.

A key component of our solution was to leverage the vast knowledge of the company’s experienced employees. These people were desperately seeking change and success. By earning their trust and confidence, we were able to help them achieve the success they desired.

As part of the process, we implemented a number of new procedures to make the assembly line more efficient:

• We created a new floor plan and consolidated two shifts into one to decrease labor costs.
• We pushed for a more comprehensive management style rather than the silo style currently used.
• We helped the client become more proactive in confronting obstacles using short interval control.
• To eliminate the need for workers to walk off the assembly line, we recommended a Kanban system to ensure all necessary parts would be available on the line as needed.
• Using capacity analysis as a baseline, we introduced new ways to work with sheet metal and unit coolers.