Deployment of Lean System in automotive sector assembly line

Automotive sector company specialised in fitting air-conditioning equipment deploys Lean manufacturing system to increase productivity and reduce its WIP (Work in Process) levels, involving a redesign of plant layout and standardisation and balancing out of workloads.

67% reduction in handling

57% reduction in lead time

30% increase in productivity

24% reduction in required space

122% improvement in process performance

NEEDS

To increase productivity.
To reduce lead time to meet market demands.
To reduce non value-added operations.
To balance out the workload between workstations.
To reduce stock in the production line.
To run a Lean application pilot programme.

IMPROVEMENT PROCESS

Identifying waste at workstations using 3M methodology.
Designing and setting up of a new layout.
Rebalancing the line and defining scenarios based on planning.
Defining new work and operations standards.
Submitting results and conclusions to Management.

Related methodologies

See methodologies

Lean Manufacturing

Adjustment to demand using minimum resources and continuously eliminating waste.