IMEG was hired by a Tier 1 automotive manufacturer to optimize production throughput. The facility is a 115,000 square foot space for both warehouse and manufacturing.
THE PROBLEM
Production throughput not meeting demands
Trapped labor
Quality concerns
Costly over time hours worked
Insufficient space at assembly stations for raw material presentation
Multiple product variations running on a single assembly conveyor
THE PLAN
Created a versatile, standard assembly line drawing that can be easily modified for future assembly line layouts
Developed a BOM for all hardware
Utilized a Project Schedule and an Action Register to manage the installation of a brand new assembly line by coordinating multiple equipment suppliers and customer internal resources
THE RESULTS
Identified annual savings of $1 million
Improved production throughput by 25%
Reduced manning requirement by 7%
Reduced quality concerns by minimizing product variation
Reduced trapped labor
Eliminated part packaging damage
Eliminated overtime
"IMEG’s staff is very open minded and willing to try new things. They provide good feedback and ask questions. The IMEG staff is inquisitive and curious about our organizations performance and what they can do from a continuous improvement stand point. IMEG’s staff is available to support any shift, weekends and long hours when needed during new product launches"
