Challenge: Our client was facing a critical production bottleneck on a new assembly line, causing delays and increasing costs per unit. They needed to identify the root cause and implement a solution without significant capital expenditure.
Solution: We conducted a comprehensive on-site analysis, employing value stream mapping and time studies. We identified inefficiencies in material flow and workstation ergonomics. Our solution involved redesigning the workstation layout, implementing a Kanban system for parts delivery, and providing targeted training for line operators.
- Results:
- Achieved a 20% reduction in assembly cycle time.
- Increased line throughput by 15%.
- Eliminated operator overtime related to the bottleneck, resulting in significant cost savings.