Wire and Cable Manufacturer
Issue:
A contract manufacturer of wire and cable assemblies had an opportunity to relocate their growing operations to an improved location. The time was very short – 90 days and this company had no experience at lean manufacturing but wanted to incorporate those principles into the layout.
Scope:
Teach the leadership lean principles and devise a new manufacturing method and layout that support lean principles in 90 days.
Approach:
The leadership team and shop floor team leaders were given a “Lean Boot Camp” that emphasized waste reduction, flow, pull and visual tools. Over a period of two weeks, data was gathered and analyzed to determine the best ways break up the complex mix of products. Another two weeks were spent developing the new layout. Some dedicated flow lines were created and other lines were created that could flow a variety of products. The planning ended with an implementation plan and a kickoff off of the 5S’s with Sorting.
Results:
The move was completed without interruption to customers and few surprises. Productivity overall is up 12% and in the dedicated areas, productivity is up more than 30% with fewer quality issues!