![]() Warehouse ManagementĪ manufacturer used an incoming warehouse for large volumes of raw materials. ![]() ![]() Results: The new changeover system resulted in 1.5 hours of added production up-time and increased throughput by more than $1 million annually. A lean consultant worked with teams across all three shifts to create a changeover that minimized downtime, enabled maintenance of the equipment for the next shift, and enhanced communication. Printing IndustryĪn automotive manufacturing company was losing production efficiency during shift changes-three shift changes per day averaged 30 minutes each. Results: Revenues improved by 20 percent, and overall productivity by five percent.Įditor’s Pick: 5 Key Lean Principles for Engineers 3. Lean 101 training was provided for supervisors, managers, and key operators, and a kanban system was installed to support just-in-time manufacturing and reduce inventory levels. To keep up with market demands, a lean team was established to work with company leaders to define their goals for the lean program. Truck Manufacturingĭakota Bodies in South Dakota builds truck bodies for the service and industrial markets. Results: Machine set-ups that once averaged five hours per machine were reduced to 35 minutes, adding about five hours of additional up-time per machine per day. A lean team found ways to streamline machine set-up and changeover requirements: a scheduling system was installed to enhance just-in-time manufacturing and upstream balance production of parts with downstream manufacturing and assembly. A cable manufacturing company wanted to reduce set-up times and shorten lead time to market. ![]()
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