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Optimized Fabrication and Assembly of Exhaust Components
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ONY is a Mechanical Engineer, Lean Manufacturing Consultant, Manufacturing Process Improvement Consultant, Project Manager, Industrial Engineer, Plant Layout Consultant, Continuous Improvement Specialist with world-class expertise in lean manufacturing, manufacturing process improvement, continuous improvement, plant layouts, Kaizen, 5S, Value Stream Mapping , Yamazumi/Line Balance, and standardized work.
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- E-mail ony@rapid-response-consulting.com
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A client in the automotive industry requested assistance to optimize the fabrication and assembly of exhaust components. The current process was plagued with production short falls, high rework and excess direct labor.
Using Value Stream Mapping and Line Balancing techniques, the process elements were analyzed and broken down. A takt time was established for the output of the cell based on current and forecast sales data. A kaizen team was formed with the operators, engineering and management to analyze the data. Training classes were initiated to educate the participants on the kaizen process. Analysis by the kaizen team resulted in the following changes:
- Improvements in the quality of the part by addressing issues with the quality of raw components, weld fixtures, and weld parameters.
- The elimination of a non value added secondary leak test operation.
- Layout changes from the line balancing activity resulted in the reduction of one operator per shift.
- Improved throughput of the line.
- The elimination of one shift.
- A continuous flow assembly line was implemented to allow the flexibility to staff the line with multiple crew sizes and achieve multiple production rates with minimal effect on the labor required per unit.
The final result was an assembly line that was able to achieve a 36% increase in productivity, reduced rework, flexible run rates and a satisfied customer.
Read other articles by this KKAI Associate:
Optimized Rework Operations of Chassis Components
Optimizing the Fabrication and Assembly of Exhaust Components
| Mechanical Engineer, Lean Manufacturing Consultant, Manufacturing Process Improvement Consultant, Project Manager, Industrial Engineer, Plant Layout Consultant, Continuous Improvement Specialist, lean manufacturing, manufacturing process improvement, continuous improvement, plant layouts, Kaizen, 5S, Value Stream Mapping , Yamazumi/Line Balance, and standardized work. | |
| Resume of MID | lean manufacturing engineer, mechanical engineer, manufacturing engineer, program manager, consultant, specialist, forensic analysis, investigation, product liability, expert witness testimony, engineering consulting services |
| Resume of GEF | industrial engineer, automotive product and process engineer, lead manufacturing engineer, value analysis / value engineering specialist, global product standardization engineering consultant, quality engineer, failure analysis, expert, engineering consulting services |
| Resume of GRW | senior lean transformation specialist, manager, consultant, specialist, forensic analysis investigation expert witness testimony, engineering consulting services |
| Resume of PHP | management consultant, business process improvement consultant, lean enterprise and continuous improvement specialist, sales and operations planner, multi-lingual trainer, change management consultant, expert consulting services |
| Resume of WVS | industrial engineer, mechanical engineer, automotive ignition systems specialist, lead acid and lithium battery consultant, manufacturing systems consultant, lean manufacturing consultant, quality improvement expert, engineering consulting services |
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Kevin Kennedy & Associates, Inc.
Rapid Response Engineering® Solutions
3905 Vincennes Road, Suite 320
Indianapolis, Indiana 46268
(317) 536-7000 voice
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