Problems: An awkward production
process and workflow in the Transit Antenna build area was
creating excessively long lead-times. Floor space in this small
factory was being used too liberally with the owner considering
purchasing a new building to meet their needs. Lean Solutions: Shop
floor layout was restructured into a single work cell for the
antenna build area. The primary "bread & butter"
products were streamlined using work instructions and the cell
was balanced. KanBans of 5 parts between operations were
instituted, later becoming 1 piece between assemblers/operators.
Visuals were posted to aid in critical processes and many
"rules" were challenged. Working closely with company
engineers we created several fixtures to make critical dimensions
and procedures mistake-proof. Many redundant tools and procedures
were eliminated from the process. Testing procedures were also
incorporated into the process for immediate feedback and quality
verification. Impact/Results: Initially
the "visual shock" of turning 26 workbenches into only
6 workbenches was almost overwhelming. Where floor space was a
highly valued premium, this was one of the great accomplishments
of the effort. Soon after the re-layout and implementation of the
new processes it became obvious that production was increasing to
unprecedented levels on many of the programs. Teamwork became the
norm, and along with a great deal of collaboration with
engineering, many programs began using modified/standardized
components. Since a maximum of 6 people were now needed to
operate the cell (including the newly integrated testing area),
the remaining 5 people were relocated to other areas needing help
throughout the plant. Because this level of success was
experienced in every area of the plant staff was not replaced as
natural attrition occurred. Sales were in a slump for this market
at last check, but should they rise again this small company will
be able to nearly double their production with about 1/2 the
staff they once employed. No one lost their job due to
improvements.
