Environmental Controls Manufacturer
Issue:
The cost needed to be lowered on a complex assembly otherwise the product would be moved overseas for assembly.
Scope:
The product took twenty four (24) labor hours to assemble. To keep the product in the U.S., the labor content needs to be less than seven (7) hours.
Approach:
The company used Optima’s “Gated” Assembly Line Methodology to move through the line creation process in a logical and methodical way that all involved parties could agree to. The process of creating this custom one piece flow assembly line from inception to commission took nine (9) months. The “U” shaped assembly line is designed to run at a takt of 35 minutes per unit in a mixed model mode. Set ups were all designed to take less than five (5) minutes on the line.
Results:
The average labor hours per unit is 5.9 – well below the required 7. The work has remained in the U.S. Escapes (bad product leaving the plant) is less that 1.5% - prior to the establishment of the line – escapes were over 5%.