Real-World Results: Manufacturing Success Stories

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Challenge: 

Automotive Manufacturing Assembly Operation Struggled with Low Throughput and High Labor, Resulting in Required Overtime Production and Missed Customer Demand

Solution:  

- Redesigned Process Steps to Eliminate Waste

- Designed a One Piece Flow Operation

- Modified Layout of Equipment to Create a Better Flow of Material and Reduce Handling Time

- Increased Pack Density of Incoming/Outgoing Materials  

Results: 

- Decreased Direct Labor Cost by 50%

- Increased Production Output by 45%

- Increased Pack Density by 92%

- Reduction of 48% Plastic Waste 

Challenge: 

Automotive Manufacturing Assembly Process Was Not Meeting Desired Profit Margin on Product

Solution:  

- Redesigned Process Steps to Create a Balanced Work Cell

- Removed 3rd Party Sub-Assembly Process

- Integrated Sub-Assembly Process into One Piece Flow Operation

Results: 

- Reduced Inventory Storage of Components

- Removed Needed Shipment and Double Handling of Sub-Assembled Component

- Increased Profit by 10%

Challenge: 

- Automotive Manufacturer Faced a Critical Storage Shortage in Their Main Warehouse

Solution: 

- Redesigned Warehouse Layout for Optimal Material Flow

- Implemented Vertical Racking to Maximize Storage

- Created Line Side Replenishment System 

Results: 

- Increased Warehouse Storage by 30%

- Decreased Forklift Travel Distance by 45%

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Challenge: 

Automotive Manufacturer Required Higher Direct Labor than Initially Planned to Meet Customer Demand

Solution:

- Removed Non-Value Added Operations

- Modified Layout to Create a Streamlined Operation

- Rebalanced and Combined Compatible Operations

Results:

- Decreased Direct Labor Cost by 50%

Challenge: 

- Automotive Manufacturer Had Assembly Process That Could Not Meet Cycle Time of Injection Molding Process. Resulting in an Offline Assembly Process

Solution: 

- Redesigned Process Steps to Most Optimal Flow

- Modified Layout to Reduce Footprint and Unnecessary Movement 

Results: 

- Eliminated Offline Assembly and Excessive WIP

- Increased Output by 20%

- Reduced labor Requirement by 25% 

Challenge:  

- Automotive Manufacturer Operated a Multi-Stage Conveyor Line. This Line Consistently Fell Short of Target Cycle Time Creating Production Delays.

Solution:

- Identified Bottle Neck in Conveyor Process 

- Integrated Additional Measures to Reduce Transfer Time

- Modified Process Steps to Reduce Time at Non-Value Added Operations

Results:

- Reduction of Conveyor Line Cycle Time by 22%