MODEL CHANGE PROCESS DEVELOPMENT

PROJECT INCLUDES:

Process Development

IMEG was hired by a tier-1 automotive seat supplier to develop processes for a major model change. This customer employs 600 people across a weld plant and an assembly plant, each with an area of 110,000 ft² and 120,000 ft², respectively.

THE PROBLEM

Volume change’s effect on takt time

Process time changes due to new product features

Work instructions need to be updated for new model

Unknown impact on manning

Unknown impact on existing process balance

Unknown impact on existing equipment capacity

New quality requirements

THE PLAN

Develop processes and MODAPTS code from product drawings to estimate process time

Observe and document new model processes

Complete capacity analysis to determine equipment needs

Determine which processes need poka yokes based on quality requirements

Update work instructions to new process

Time study and pace rate trial builds to validate calculations

THE RESULTS

Developed an efficient process that resulted in a successful and well executed new model launch

Developed new work instructions with poka yokes for 72 stations across 9 production lines

Identified new equipment to be implemented in order to provide necessary capacity

Manning levels and process balance were accurate and required minimal tweaking post launch