Contract Metal Finisher
Issue:
The main process line was at times starved for product and at other times overwhelmed. This condition was leading to unstable lead times and dissatisfied customers.
Scope:
Develop a method to create a pull of product in an environment that has wild swings in demand. Lead times must be less than three (3) days with reduced overtime while maintaining or improving quality levels.
Approach:
A cross functional team with representation from all shifts was brought together two days a week for one month to develop and implement a pull system. They created visual areas at the main line and in each racking/unracking area. Empty “squares” meant work needed to be completed in that area, while full “squares” told workers to flow to other areas and assist as needed. The team needed 5S and a great deal of discipline to make the system work.
Results:
After ninety (90) days – lead times were averaging 2.4 days and overtime was at its lowest levels in over a year. The quality level went down in the first thirty (30) days but this was attributed to workers flowing to areas they had never worked in before. After thirty (30) days the quality level came back to normal levels and after ninety (90) days a slight improvement was seen. The team is working on more detailed standard work to drive the quality even higher.