Táktica Lean & Kaizens

As a supplier in an integrated industrial complex, Dow Automotive was supposed to respond quickly to the variability of its client’s production. As the client works with inflexible targets, any failure in any link of its manufacturing chain would seriously interfere with an entire production system. There was no room for error.

Together with a team appointed by Dow, we investigated the company’s production targets and processes, and came to the conclusion that it was necessary to redesign the layout of the plant and its Information and Physical Logistics systems. This included determining the inventory of each part and reviewing their storage system, packaging designs, transportation system, supply routes, and supermarket figures, as well as preparing specific FIFO and Kanban charts. In addition, we introduced a standardized work system in the company, by which each group of assembly and logistics operators would be self-managed and empowered to decide their own production schedules and use the resources necessary to meet their targets.

As a result of this joint effort with the Dow team, which included training involved company employees, the plant gained increased agility and flexibility in its integrated operation within the industrial complex. The full support of management, from the very beginning up to the implementation of the project, was a key factor for its success. Today, Dow stands out as one of the most efficient suppliers in the Ford Northeast Complex, and serves as a model of factory-floor logistics and organization.

”The Taktica team always demonstrated firmness, competence and commitment in their effort to ensure that Dow Logistics and Production would rank among the best in the entire Ford Northeast Complex.”

Carlos Roberto Pereira
Plant Manager
Dow Automotiva