Sector: Automotive
1st Tier Supplier of Automotive Mechanical Components

Scope:
Post new model launch this automotive manufacturer was forced to employ additional staff (agency) in the assembly facility, to produce the higher than expected sales volumes and manage additional engineering containments for quality. In order to avoid employing the agency staff on full term contracts it was necessary to reduce the number of processes within the facility.

LMR Lean specialists had the challenge of reducing the number of processes to assemble the product by 50 and achieve this in a controlled manner that introduced documented standardised work and process balance boards (Yamazumi). A further demand was not to adversely affect quality.

Application:
LMR, after negotiating terms with the union, and communicating fully the intent of the process to be undertaken, formed a core team of skilled team leaders, engineers and key operators to deliver the project. Starting at the nearest point to the customer, and working back through the assembly lines, LMR and the core team built quality confirmation stations to ensure defects did not reach the customer. This temporary measure was removed 3 weeks upon completion of the project. Each station was analysed for waste content with the support of the team leader of the section and the operator performing the current standard. Upon completion of the analysis, Work Element Sheets and Standard Work Charts were drafted for review by all shifts. Upon approval (36 hours per station) the Standardised Work was authorised and became current. With a lag team to secure training of team members in the new standard and to build the Yamazumi, the lead team would move to the next station and repeat the process. After 10 weeks the project team were able to evaluate the impact of the changes on key indicators related to Safety, Quality and Delivery.

Results:

* Reduced No of processes by 56 in 10 week period
* Cost saving of £1,400,000
* All processes standardised – SWC, WES & Yamazumi
* All lines balanced to within Takt time
* 20% reduction in line side inventory
* Waste reduction (7 wastes eliminated)

ROI on LMR resource 23:1.