IMEG was hired by a Nebraska based Irrigation System & Road Safety Infrastructure Manufacturer to improve the flow and capacity in their galvanization process.
THE PROBLEM
Bottlenecks identified due to manual intensive process (material racking and de-racking)
Limited space for end process (de-racking) and material handling
No defined product sequencing
Idling of galvanization process due to problems mentioned above
THE PLAN
Group products based on the product families
Work sample the racking and de-racking process based on different part families
Utilize new racking fixture to increase the galvanization capacity
Mobilize manpower on racking and de-racking process depending upon various product families
Develop an efficient product sequence for smooth flow of product without idling whole galvanization
Develop optimal racking capacity of each product family for new racking fixture without exceeding crane loading capacity
Develop a simple guideline for operators and team leader with dos and don’ts for sequencing of products
product flow sequencing
lean
THE RESULTS
Improved galvanization capacity by 38%
Achieved daily demand goal for irrigation system products
Improved the flow of the products in the galvanization process
Optimized the use of available de-racking space
Improved 5S in the galvanization area
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