Manufacturer Reduces Prototype Production Time By 77% With GLSS
Ohio
Manufacturing
Production
77%
PROJECT SUMMARY
- Business Case: New model SKUs will reach market faster. Would also reduce Work-in-Progress time where parts are left around the facility and not completed and handed off to the next stage.
- Root Cause Analysis:
- Without proper use of machines and tools, materials are not produced correctly to meet part tolerances.
- Solutions Implemented:
- Improve operator standard procedure documentation to enable correct machine and tool usage.
- Create a tracking system so all parties are aware of what stage of the process each prototype is at.
- Project Result:
- The Fabrication department now prioritizes prototype production.
- The process proves out the concept of keeping the components of a SKU together throughout the production process.
- Lead times were reduced from 30 days to 7 days—a 77% improvement!
- The problem: Lead time for prototype production was taking 30 days, leading to delays, increased costs, and unsatisfied customers.
- With GLSS Green Belt Training & Certification, this manufacturer developed standard operating procedures and implemented a robust tracking system, reducing lead time to 7 days—a 77% improvement—and allowing them to deliver products to their customers faster than ever before!
Timely prototype fabrication is crucial for meeting project deadlines and launching new products on schedule. Delays in prototype production have led to postponed product releases and potential market opportunities lost. By speeding up the prototype creation process, they aimed to enhance the overall productivity and maintain a competitive edge in the market.
The root of the problem seemed elusive, but the impact was clear: delays, increased operational costs, and strained relationships with their clients. They needed to find a solution quickly, but more importantly, they needed to ensure that the changes made would be sustainable in the long run.
After an in-depth analysis, they discovered that the root causes of our problem were multifaceted.
- Machines and Materials Not Meeting Part Tolerances: The existing machines and materials used in the fabrication process were not capable of producing parts that met the required tolerances. This led to multiple iterations and reworks, significantly extending the time needed to complete prototypes.
- Inadequate Process Tracking: There was a lack of a comprehensive tracking system to monitor the stages of the prototype fabrication process. This resulted in poor communication and coordination among the team members, further contributing to the delays.
To address these issues, they utilized GLSS Green Belt Training & Certification, leveraging our approach to guide them through the necessary improvements.
- Improved Operator Standard Procedure Documentation: They revised and enhanced the standard operating procedures (SOPs) for machine and tool usage. This documentation provided detailed instructions and guidelines, ensuring that operators used the machines and tools correctly to achieve the desired part tolerances. Training sessions were conducted to familiarize operators with the updated SOPs, promoting consistency and accuracy in the fabrication process.
- Creation of a Tracking System: They developed and implemented a robust tracking system to monitor the progress of each prototype through the fabrication stages. This system provided real-time updates and visibility, enabling all stakeholders to know exactly where each prototype was in the process. This transparency facilitated better coordination and timely interventions, reducing delays.
The results of their efforts were nothing short of transformative. Lead times were reduced from 30 days to 7 days—a 77% improvement—which allowed them to deliver products to their customers faster than ever before. Their production efficiency improved, and they saw a significant reduction in operational costs. Perhaps most importantly, the morale of their team improved as well. By standardizing processes and improving communication, they created a more cohesive and motivated workforce, ready to tackle any challenges that came their way.
This project was a turning point for their organization. The innovative instructional design and content provided by GLSS Green Belt Training & Certification not only helped them address our immediate challenges, but also positioned them for long-term success. By driving results quicker and more effectively, they were able to stay competitive in a demanding industry.
*We value our clients’ confidentiality. While we’ve changed their names, the results are real.
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