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Optimized Rework Operations of Chassis 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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- Call (317) 735-4773
- E-mail ony@rapid-response-consulting.com
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A tier one client in the automotive industry requested assistance to optimize the rework operations of chassis components. The current rework process was plagued with production short falls, secondary rework, safety issues and excess direct labor.
Using 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:
- The current batch process was one person moving a 75 lb part from a conveyor to their work station repairing welding the part then moving it back to another conveyor. The current process had issues with safety and missed repairs that needed to be repaired down stream. In the new process 4 weld stations were set in continuous flow between the two conveyors. Each welder using lift assist would remove the part from the previous welder’s holding station repair weld one quarter of the part and send it on to the next station. After going through the four repair weld stations the part moved on to the next operation.
- As a result of only having to repair one quarter of the part the fttq of the repair weld operation went from 40% to 95%.
- Strains do to lifting the part were eliminated.
- Reduced the number of primary repair welders from 7 to 4 and secondary inspection repair welders from 3 to 1.
The final result was a repair weld operation that was able to achieve its production goal with a reduction in safety incidents and in the number of operators required.
Read other articles by this KKAI Associate:
Optimized Fabrication and Assembly of Exhaust 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, expert consultant |
| Resume of GEF | value analysis, value engineering, expert consultant |
| Resume of GRW | lean transformation expert consultant |
| Resume of PHP | lean enterprise, continuous improvement, expert consultant |
| Resume of WVS | automotive ignition systems, lead acid, lithium battery, expert consultant |
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Kevin Kennedy & Associates, Inc.
Rapid Response Engineering® Solutions
3905 Vincennes Road, Suite 320
Indianapolis, Indiana 46268
(317) 536-7000 voice
(317) 536-7220 fax