Benchmarks & Client Cases
Line Design in Automotive Assembly
The Challenge
Problem
• Low productivity of production and logistics teams
• 50 000m2 of extra rented warehouse space
• Necessary to adjust capacity in order to absorb new models to be produced
Root Causes
• Unbalanced combination of references to be produced on each production line
• Poor usage of available space, with inefficient layouts and structures
• Complex flows for movement of information and materials internally
• Packaging of material not adapted to specific product characteristics
The Solution
• Project management using Mission Control Room, KAIZEN™ Events and Task Force Initiatives
• Layout organised according to fishbone concept: Line – Pre-Assembly – Kitting – Warehouse – Receiving Gate
• Follow-Lead Kitting, Pick-to-Light and Guided Trolley
• Implementation of Pallet-on-Wheels, Mizusumashi principle and Manual Transports
The Results
The project had a Payback period of 8 months with annual savings surpassing £38 million.
Production Productivity
Production productivity increased by 27%, through the elimination of non-value-added activities
Logistics Productivity
Logistics productivity increased by 29%, through the optimisation of layout and containers
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