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Case Study 6 - High Volume Casting & Machining – Lean Deployment

Client: Manufacturer of high volume, precision automotive components

Challenge: Reduce labor input and scrap while improving delivered quality in a union environment with a company in bankruptcy

Our Role: Develop, implement and manage an improvement plan for multiple work cells and multiple plants utilizing classic line balancing tools to reduce costs, improve the quality

Implementation Strategy:
1. Train Associates & conduct line balancing on highest volume work cells
2. Conduct brainstorming to develop cell layout improvement concepts
3. Utilize automation when appropriate to improve productivity
4. Deploy standardized tool change methodologies

Results achieved:
1. Achieved 50% Productivity Gains in affected Work Cells
2. Scrap Reduction from 5% to less than 0.5%
3. No missed delivery to customers

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