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75% improvement in productivity through the deployment of pulled flow work cells

Automotive sector company deploys pilot pulled flow work cells in two of its assembly lines.

75% increase in productivity (Line 1)
50% reduction of WIP (Line 1)
45% saving used surface (Line 1)
71% increase in productivity (Line 2)
76% reduction of WIP (Line 2)
55% saving in space (Line 2)
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NEEDS

  • To reduce the lead time and stock of work-in-process (WIP).
  • To increase productivity.
  • To balance out the workload amongst different work stations.
  • To run a pilot Lean programme.

IMPROVEMENT PROCESS

  • Analysing the current situation.
  • Designing and setting up the layout of the two work cells.
  • Detecting waste in the workplace using 3M analysis.
  • Defining new work standards.
  • Submitting results and conclusions to Management.
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Related methodologies

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Lean Manufacturing

Adjustment to demand using minimum resources and continuously eliminating waste.
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