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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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