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Manufacturer of Power Garden Appliances - TX
To Improve Manufacturing Processes
The Challenge:
- Mold changeover
times of Injection molding machines are taking days instead
of minutes.
- Existing cells
are inefficient and causing inventory accumulations and backlogs
of customer deliveries.
- Seasonality affects
greatly the level of demand.
The Approach:
- Performed Kaizen
events to improve cells and layouts, also mold changeover times.
- Trained and developed
Kaizen teams focusing on the high opportunity areas.
The Solution:
- Rapid implementation
of all ideas in order to change culture.
- Focus on the Plant
SBU most in need of improvement
- Targeting the Injection
mold changeover taking the longest time
The Results:
- Improved 15 subassembly
cells in three weeks going from 78% productivity to 98%.
- Implemented the
new layout during a shutdown resulting in a streamlined flow
and elimination of one day of inventory.
- Implemented changeover
methods that reduced the time from 29 hours to 1 hour.
- Implemented a six-month
plan for improving mold changeover time in all 58 molding machines.
The goal is one hour changeover.
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