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Problem

Custom manufacturing lead times needed to be cut in half in order to break into new market without product redesign or investment in inventory.

Approach

  • Focus on pacemaker process to establish flow.
  • Establish all floor personnel design team & improve their capabilities to design flow solution.
  • Create environment of floor-controlled change in step with new accountability structure.

Recommendations

  • Create a semi-continuous flow process (pulse line) for 60-100 ton custom engines.
  • Create integrated visual control environment that is takt time based.
  • Create visual response system with support teams.

Results

  • 25% reduction in steps to produce at startup of pulse line.
  • Created floor leaders capable of high lean impact and authorized to make improvements, a complete shift in organization culture, for multi-year transformation on their own.
  • Company-wide visual measurement of performance and response.