Lean Process Optimization

Value Stream Map

Multinational Industrial Equipment Manufacturer

Overview

Client experiencing waste, delays and retrofit challenges in defined operations. Overall goal to enhance site organization, staffing and workload balancing to meet daily demand efficiently and cost-effectively.

Project Achievements

1. Conducted phase 1 assessment of current state evaluating target production vs. average and Identifying root causes for waste, delays and bottle-necks.

2. Executed a phase 2 implementation plan supporting the designated rebalancing initiatives, machine buffering strategy, and investment in CapEx projects.

3. Conducted and validated a Return-On-Investment for the project outcomes and recommendations.

Bottom-line Results

20% REDUCTION IN OVERTIME

Utilizing our value stream mapping process with Yamazumi analysis and diligent identification of effective solutions, we assisted our client in achieving a 20% reduction in annual OT hours.

32% UPD THROUGHPUT INCREASE

Implementation of workforce rebalancing, standardization of work, and introducing a buffering strategy, we enabled our client to obtain a commendable 32% increase in productivity.

$12.5M ANNUAL SAVINGS POST IMPLEMENTATION

After reducing OT, increasing productivity, and evaluating CapEx projects, our efforts resulted in a substantial annual savings of $12.5 M.