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THE COMPANY A manufacturer of capital equipment for the pre press industry, a wholly owned Subsidiary of a major Japanese Corporation. THE CHALLENGE The final stage of product assembly involved fitting a series of outer skins manufactured mainly from pre-formed sheet metal. Parts were packed individually, delivered in batch quantities from the manufacturer and stored both at line side and in the goods inwards area. The "skinning" operation could not be completed in less than six hours per production unit. THE STRATEGY Our strategy was to work with a group of individuals from across the manufacturing organisation (line staff, purchasing and engineering) to detail and measure the work and the waste involved and to devise and implement a plan for improvement. THE BENEFITS The project took three months to complete
QUOTES FROM THE STAFF "I don’t go home exhausted at the end of each day now, I’m never short of parts and my work area is always tidy. I can see where everything is and I don’t spend half my life wandering round the factory looking for things and moving things around." The Operator "I really thought our supplier would give us trouble over this. As it is, he has been able to realise a tangible benefit because although he now delivers on "pull" (about every two days) he has saved all the packing costs and we don’t have to argue who is responsible for the damage. There isn’t any." Buyer |
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