Problem Description

Unorganized work areas result in non-value added activities, unnecessary safety risks, and decreased morale and welfare of the workforce.

Corrective Action Methodology

• Implement a company wide 5S/Safety Program using the Hoshin Planning Process
• Develop and implement a 5S scorecard (100 point scale), and set goals
• Identify and develop improvements plan based on 5S audits
• Develop a rewards and recognition program

Results and Benefits

• 28% reduction in non-value-added activities (travel, transportation, motion, inventory)
• Average 5S scores improved from 34 points to 75 points over a 6 month period
• Improved workforce morale and welfare (rewards and recognition)
• Passed all ISO audits

Problem Description

Material flow throughout the manufacturing process exceeds available floor space.

Corrective Action Methodology

Use Value Stream Mapping, Takt Time, and Spaghetti Diagram to analyze material flow and identify process improvements.

Results and Benefits

• 14% reduction in direct labor
• 32% reduction in manufacturing floor space
• 24% reduction in operator travel distance
• 41% reduction in part travel
• 60% reduction in Manufacturing Lead Time

Problem Description

Material flow throughout the manufacturing process exceeds available floor space.

Corrective Action Methodology

Use Value Stream Mapping, Takt Time, and Spaghetti Diagram to analyze material flow and identify process improvements.

Results and Benefits

• 19% reduction of material travel
• 5000 square feet of floor space created available for production
• Work cell shipped 100% of all past dues within three months
• 188% additional capacity for conformal coat department
• Reduced cost of transportation for conformal coat by 8%

Problem Description

Existing Stockroom Layout & Processes does not facilitate efficient flow of material to / through manufacturing.

Corrective Action Methodology

• Develop procedures and work instructions; train stockroom / manufacturing personnel
• Develop metrics and root cause pareto; implement Cycle Count Process
• Reorganize the stockroom; implement Kanban System

Results and Benefits

• 40% reduction in material labor (kitting time)
• 40% reduction product cycle time
• 60% increase in inventory turns