Purpose
Increase the efficiency of the production line while maintaining the same floor space
An expert in the assembly of distribution boxes, supplying high-end specialized products to leading engineering and manufacturing companies, and providing service support throughout the entire product lifecycle. The company holds a strong position in the local market and has been in operation for nearly 20 years.
Project Challenges
- Constantly changing project documentation
- Customer documentation often unclear or incomplete
- Staff shortages in the engineering department
- Limited space on the production floor
- High onboarding threshold for new employees
- High level of skills and experience required for assembler and electromechanical technician positions
Through the Customer's Eyes
The biggest challenge during the KAIZEN workshops was developing a common solution that would benefit all departments. The key turned out to be combining office work with shop floor activities and engaging the operators. Throughout the project, additional needs emerged, such as changes in workstation layout and optimization of material delivery. Working with the consultant helped structure our activities, clarified task distribution, and engaged the team. The workshops brought greater process transparency, improved collaboration, and tangible improvements.
Production Engineer
Implemented Solutions
- Dividing production processes into stages
- Identifying, simplifying, and standardizing repetitive processes
- Delivering materials directly to the assembly point
- Switching to a parallel work system with team-based work (working in pairs)
- Changing internal logistics and material delivery methods to the line
- Addressing staff shortages and reorganizing work in the engineering department
- Implementing onboarding and TWI (Training Within Industry)
- Creating a material supermarket
- Redesigning the layout
Tools Employed
- Kaizen Workshops
- Work Standardization
- Kanban
- 5S
- TWI (Training Within Industry)