IMS Solution:

The IMS solution was to switch production methodology.

The traditional production processes were ‘batch’ which resulted in insufficient local accountability for the quality of work and many opportunities for the product to be damaged while sitting in queues or being transported between production units.

‘Cellular’ manufacturing had the potential to address these damaging issues and also provide local management with data to address root causes of quality issues.

Working in collaboration with the local production and supply chain management the IMS project manager designed a pilot production cell with the aim of reducing waste. The pilot results were as follows:

• Finished Yield increased from 75% to 87.4%
• Production velocity reduced from 4 Weeks to 4 days
• Availability of key production facilities was maximised (increasing overall factory capacity)
• Operator productivity was increased

Following on from this success, the IMS project manager was asked to continue to work with the organisation’s management to transform the entire production facility to lean, cellular manufacturing, specifically:

• Calculating the number of cells required to service projected production volumes
• Designing ‘to be’ layouts and process flows
• Designing in-line go/no go quality controls (intended to drive local accountability for production quality and eliminate inspection steps)
• Building cell teams and associated training plans
• Project managing the implementing of the complex physical layout changes while maintaining production
• Training cell teams in new methods of working

The performance improvements seen in the pilot study were replicated in the full-scale project and continuous improvement routines now owned by local cell management continue to drive operational and financial benefits.

For more information on this case study contact IMS!