About

24/7 manufacturing with ~ 450 FTEs.

Objectives

• Throughput increase;
• Redesign of planning and scheduling;
• Reorganization of production area.

Analysis

An in depth audit of current processes and procedures in all production areas:

• Multiple interviews with top and middle management;
• Created ‘Value Stream Mapping’, area layout and so called ‘System Critique’;
• Detailed full shift function observations;
• Challenge the standard – clocked and redefined existing machine capacity standards.
• Performed multiple statistical and functional studies:
  • Activity lists;
  • Flexibility & Responsibility matrices (charts);
  • Supervisory studies;
  • Operator’s detailed studies;
  • Ratio Delay;
  • Variance;
  • Capacity / Utilization, etc.

Design & Implementation

• At the end of our second month on site, top client agreed on 22% of productivity increase to date;
• Developed and deployed resource Master schedule;
• Optimized area layout and production planning methodology.
• Maintenance – applied TPM approach and deployed action plan procedures for emergency stops, SMED;
• Disciplinary measures as shift hand over, breaks, etc.;
• Overall productivity was increased with ~40%.