Benchmarks & Client Cases

Line Design in Automotive Assembly

The Challenge



• 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


• 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

Are you interested in Kaizen Institute's consulting services?

We assist client teams in achieving great results by putting breakthrough paradigms into action.

Are you interested in Kaizen Institute's training courses?

Kaizen Institute's distinctive training program includes learning the theory and practice and gemba visits.

arrow up