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As a result of increasing demand, a large Irish-owned engineering company in the East of Ireland, manufacturing commercial vehicles, wanted to scale their business while adhering to their customers’ three main requirement of:
As the company was experiencing significant growth, the present operating model was generating bottlenecks and there was a concern that orders would be delayed which risked the strong reputation the company had developed. The company wisely decided to tackle three areas to reduce the bottlenecks and delays. The three areas were:
1. On-Time Deliveries
2. Lead Times
3. Order backlog
Initially a large amount of data was collected to accurately measure the current state. Takt times and cycles times were key targets for improvement to determine line balance. The number of stages in the manufacturing process was analysed to determine if the 7 stages in the process were necessary.
A targeted 6Ss programme was completed to reduce H&S risk and to eliminate time wastage. Visual Boards were introduced at all stages of the manufacturing process to identify problems to be resolved expeditiously. This laid the grounds for standardisation of work practices. The introduction of agreed KPIs focussed minds on the business critical deliverables.