Case History 01
Lean manufacturing
Lead time reduction and
variance stabilization
WTCO
www.wtco.it
Context
Introduction
The target of the company was to improve the service level to the customers in particular way in
relation to these aspects:
Ø Improving the delivery time with a reduction of the lead time from 10 to 3 day
Ø Stabilization of the delivery time variation from 9 to 1 day
Operating area
The operating area started with a focus in a workstation called “Prototype lean workstation”,
with a target to extend the project to the all shop floor
The goals in the prototype lean workstation, were to be achieved in 3 months.
The prototype lean workstation, must work in a shop floor were was implemented an MRP
software.
The main actions were focusing on: Layout re-design of the workstation, identification and KPI
monitoring, Visual management tools for production planning and controls, pacemakers
identifications and implementation of a pull system.
WTCO
www.wtco.it
Goals
Considering the family product selected to start the lean project
KPI
Lead time
10,14
3,00
Delivery time variation
9,27
1,00
WTCO
www.wtco.it
2
Activities and tools used
Ø Creation of a team work and training courses to the operators
Ø Definition of the main KPI and develop of the control system
Ø Project and implementation of the business model to bring together the lean workstation in
a shop floor MRP environment
Ø Sharing of the product technical specification
Ø ASIS and TOBE Spaghetti chart
Ø New macro and micro layout design of the lean workstation
Ø Kaizen actions plan and process improvement proposals (PIPs)
Ø Improved ergonomics in the movements of the operators
Ø New lean layout of the workstation implemented in 45 work days
Ø Pacemaker identifications and pull process implementation
Ø Implementation of visual management tools for production planning and controls
WTCO
www.wtco.it
3
Results achieved
Project
start
GG
New lean
workstation
start
20
15
KPI
GOAL
!!
10
Achieving goals
1 month later the
start of the new
lean workstation
5
3
Lead time target
1
Delivery time variations target
Lead time days
Delivery time variation days
Internal lead time reduction from 10 to 3 days
Delivery time variation stabilization from 9 to 1 day
WTCO
www.wtco.it
4