A comprehensive improvement plan addressed these issues, emphasizing process optimization, automation, and lean production principles:
1. Analysis of Current State and Waste Identification:
- Process Walkthrough & Bottleneck Identification:
- Conducted a comprehensive review of the finishing process to pinpoint bottlenecks and inefficiencies related to motion, transport, and waiting times.
- Motion Waste Reduction:
- Streamlined production flow by consolidating steps into a linear process, eliminating unnecessary movement.
- Reduced cross-departmental backtracking by applying lean layout principles to reorganize workstations.
- Transport Efficiency Optimization:
- Transitioned to high-density transport carts with 50-70 parts capacity, significantly enhancing transport efficiency.
- Minimized idle transport times by synchronizing material handling schedules with production cycles, ensuring smoother flow.
- Wait-Time Reduction:
- Addressed delays by optimizing workload distribution across workstations, minimizing downtime.
- Implemented floor markings for cart positions and flow indicators to guide material movement and improve overall process visibility.
2.
Capacity Requirement Analysis:
- Evaluated current production needs and growth projections to determine necessary capacity upgrades. Conducted a thorough analysis of color usage and established an improved matrix for production scheduling to better align with operational demands and reduce scheduling conflicts.
3.
Process Streamlining, Lean Implementation and Eliminating Redundancy:
- Adopted stricter lean production methods to reduce waste and enhance workflow.
- Revised the production schedule with improved grouping based on color categories (e.g., stains, paints, and primer colors).
- Combined production lines to reduce duplication and increase process efficiency.
4.
Automation Integration:
- Introduced an automated spray machine and sanding system through a structured, multi-step process:
- Specification Vetting: Collaborated with stakeholders to define precise requirements, such as automated gun and sanding head positioning for different profile types and seamless material handling with an automated destacking unit.
- Selection Process: Conducted comprehensive tests at supplier facilities, comparing machine performance against specifications to establish a comparison matrix and select the best fit.
- Implementation: Oversaw installation and commissioning, ensuring proper integration into existing workflows and alignment with lean production principles.
5.
Operational Changes and Workforce Support:
- Developed job descriptions for new roles created by automation.
- Prepared an implementation plan to transition to a dedicated linear-processing cell.
6.
Ramp-Up and Standardization:
- Designed a ramp-up curve for production, followed by on-site support during the transition phase.
- Created standardized work procedures to ensure consistent productivity.
7.
Continuous Improvement Framework:
- Established key metrics for cart movement and overall throughput to monitor performance.
- Implemented systems to facilitate ongoing process improvement and enhance management oversight.