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Approach: Process: Scenarios

Targeted Events

Taking a Closer Look

Using Events to Target Problems

With productivity down and inventory up, a global manufacturer needed to take a closer look at its nine European manufacturing plants.

To pinpoint the problem areas the company scheduled a series of dedicated events, including setup-reduction events to reduce internal setup time and standard work events to improve productivity in assembly cells.

The transformation created standard work methods for setup procedures, which reduced variation in times, and a setup wheel to increase the schedule frequency of part numbers, which reduced lead times and inventory.

Once the changes were in place, the plants saw impressive reductions in staffing of 50% in each cell, in inventory of 30% in one year and in setup times from 20-40 minutes to 6-14 minutes per setup.