Kaizen Institute - Success Story
Aerospace
Flow Management, Productive Maintenance
Client Profile
India's premier aerospace company, manufactures precision machined parts & sub-assemblies for aerospace & automotive sectors
Improvement Potential
- Weak 5S implementation
- High work in process
- High finished goods inventory
- Poor implementation of visual management systems
Project
The main target of the KAIZEN™ project was to improve the transportation efficiency. Amongst others, the project included the following necessary actions:
- Designing straight aisles for the ease of material movement
- Improving the material flow (raw material in & finished goods out)
- Implementation of a process ownership model – raw material to finished goods
- My machine concept
- Multi manning & multi skill approach
Our Approach
- Lean cell design and implementation
- Reduced inventory through cell formation and one piece flow
- Reduced motion: High frequency usage items at Point of Use
- Reduced waiting: Tools in cell, self approval of the samples in the cell
Key Results
- Changeover time reduced by 25-50%
- Production space reduced by 30-35%
- Direct labor reduced by 20%
- Production costs reduced by 20-30%
- Output shift increased by 12%
- Value added ratio increased by 10%
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