Benchmarks & Client Cases

Line Design in Automotive Assembly

The Challenge

final-assembly-layout
cab-trim-assembly-layout

Problem


• Low productivity of production and logistics teams

• 50 000m2 of extra rented warehouse space

• Necessary to adjust capacity in order to absorb new models to be produced



Root Causes


• Unbalanced combination of references to be produced on each production line

• Poor usage of available space, with inefficient layouts and structures

• Complex flows for movement of information and materials internally

• Packaging of material not adapted to specific product characteristics

The Solution

Fishbone assembly Concept

material-handling-solutions-kits

• Project management using Mission Control Room, KAIZEN™ Events and Task Force Initiatives

• Layout organized according to fishbone concept: Line – Pre-Assembly – Kitting – Warehouse – Receiving Gate

• Follow-Lead Kitting, Pick-to-Light and Guided Trolley

• Implementation of Pallet-on-Wheels, Mizusumashi principle and Manual Transports

The Results

The project had a payback period of 8 months with annual savings surpassing $38 million.


Production Productivity

Production Productivity

Production productivity increased by 27%, through the elimination of non-value-added activities

Logistics Productivity

Logistics Productivity

Logistics productivity increased by 29%, through the optimization of layout and containers



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