Kaizen: Flow
Scenario:
• Production failed to meet increased demand
• Need to increase production from 150 to 200 machines per month
• Increase of service level from 70% to 95% of the delivered products.
What has already been done:
• Study of the assembly process
• Record of assembly times
• Spaghetti diagram of the operators
• Implementation of a new layout to bring processes closer together
• Definition of a new work process
• Determination of the ABCXYZ curve for the products
• Analysis of supply flow
• Reorganization of materials in the production area
• Implementation of kanban for mechanical parts and purchased goods
Organization and Separation of materials into assembly kits:
Rotor inventory support (buffer): New layout for the supermarket:
Workplace organization: Organization of the kit assembly bench:
New layout:
Results:
Takt Time vs. Bottleneck
