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Improvement in Throughput
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Improvement in Equipment Uptime
Challenge
Poor labor Productivity and equipment downtime had translated into declining profitability for 18 months prior to our engagement. In addition, increasingly random maintenance emergencies had become a catalyst to sudden production schedule changes and an unbalanced workforce. Management and Supervisory coverage was not correctly distributed across the one million square foot facility that operated 24/7, leading to consistently poor production performance and customer service levels.
Solution
Synergetics completed an implementation project that would focus on the following deliverables:
- Installed Management Operating System (MOS) tools to track performance and identify improvement opportunities
- Train front line supervisors on basic leadership and Lean principles
- Reconfigure line layouts and balance work activity to maximize labor utilization
- Established pre-staged Kanban lanes with BOM components for each production work cell
- Design and installed MRO inventory management system to control inventory, reduce costs, and reduce obsolete / expired material with ABC analysis
- Identified and cataloged 15,000+ critical spare parts to minimize lost time searching for parts
- Implement Preventative Maintenance program for equipment reliability and up time improvement
- Installed Computer Maintenance Management System (CMMS) to monitor PM completions
