Problem:
Customers were upset because the wrong products were being shipped to them. Final processing is very unorganized with no standardization causing products to become mixed.
Mission:
Map out the final processing process
Organize and standardize the work flow utilizing “best practices”
Mistake proof the process flow to permanently correct the mixing of product
Approach:
Charter a final processing lean team.
Provide lean training.
Create a current state process video.
Develop a current state layout.
Map and Measure the Current Value Stream.
Identify the non-value added tasks.
Map the future state.
Redesign the process utilizing the 5S principles.
Create a new process video.
Present the results to the lean steering team.
Lean Techniques Taught and Utilized:
Lean Manufacturing
Value Stream Process Mapping
5-S Workplace Organization
Visual Factory
Kanban Pull Replenishment System
Results Realized:
Control of product
Tour ready every day
Increased Capacity
Increased On Time Delivery