Project of the Month


"Streamlining the Finishing Process“

How Lean Strategies and Automation Boosted Efficiency and Capacity

INITIAL SITUATION

The linear-part finishing process at the facility was heavily reliant on manual labor, resulting in inefficiencies and delays. The key challenges included:

  • High Labor Dependency: Over 1,200 linear components were sprayed and sanded manually, consuming significant time and resources.
  • Product Variety: A wide range of profiles and colors, with over 50 unique color options (including stains, paints, and fully customizable colors), added complexity to the process.
  • Inefficient Transport: Low-density transport carts are limited to carrying 10-20 parts due to manual handling.
  • Non-Streamlined Workflow: The production process followed a zig-zag pattern, leading to wasted motion, transport, and waiting time.
  • Extended Lead Times: Manual processes and disorganized workflows caused prolonged internal lead and processing times.

APPROACH

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.


CUSTOMER BENEFITS

The implementation of these strategies delivered substantial improvements:


  • Increased Efficiency:
    A more streamlined workflow reduced distances and eliminated unnecessary steps. Adjusting the flow and utilizing high-density carts increased daily production within individual finishing rooms from 500 to 650 parts (before machine implementation).


  • Labor Savings:
    Automation of spraying and sanding processes reduced manual labor requirements by more than 60%, complemented by the automated destacking unit, and reduced redundancy across multiple finishing rooms.


  • Enhanced Capacity:
    Transitioning to automated processes enabled the system to spray up to 15 parts per minute, significantly increasing throughput and overall capacity by more than 30%.


  • Improved Management:
    Introducing performance metrics allowed for better tracking and decision-making.



Through these interventions, the production performance of the linear-part finishing process was significantly enhanced, enabling the facility to meet increasing demands with improved efficiency and reduced costs.