Problem:
A traditional push manufacturing system is causing excess raw materials and work in process inventories. Therefore costs are high, lead times are long and customer deliveries are not always on time.
Mission:
Identify and quickly correct sources of non-value added time.
Design out bottleneck processes.
Create a pull system that replenishes inventory on customer demand.
Increase capacity without increased staffing.
Approach:
Map and Measure the Current State Value Stream.
Identify the bottleneck processes. - The production processes could make product faster than finishing and shipping.
Map Future State Value Stream and Transition Plan.
Charter and train three Lean Transformation Teams: - Kanban Implementation Team - Production Process Improvement Team - Finishing and Shipping Process Improvement Team
Lean Techniques Taught and Utilized:
Value Stream Mapping
Kanban Pull Replenishment System
5-S Workplace Organization
Cellular Manufacturing
Quick Changeover
Results Realized:
Increased Capacity > 10%
Increased On Time Delivery to > 95%
Reduced Waste
Improved Lead Time
Reduced product costs
Reduced Raw and Work in Process Inventories
Improved employee morale