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Automotive-125
The Situation:
Manufacturer of steel wheels for trucks and trailers was experiencing increasing costs and reduced profits in a growing market with increased pressure from customers to meet delivery and cost requirements.
The Driver Goal:
- To achieve a 25% improvement in productivity by the end of 3rd Q next year
- To improve direct labor efficiency by 25% by the end of 3rd Q next year
- To achieve schedule attainment of 100% by the end of 3rd Q next year
Actions Taken:
- Initiated a Goal Roll Down and translation process
- Designed and implemented a Management Operating and Shop Floor System as well as the required training programs to integrate management and supervisory staff in its use
- Implemented Lean Manufacturing principles
- Initiated a Preventative Maintenance Program
- Introduced a Barrier Identification and Resolution process which involved shop floor employees
- Designed and implemented Quality System with new roles and responsibilities
The Results:
- Achieved 32% improvement in productivity
- Improved direct labor efficiency by 37%
- Trained 187 employees in the new processes
- Achieved 85% schedule attainment
- Reduced equipment breakdown hours by 49%
- Reduced quality problems by 53%
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