Background
In the face of a pandemic-fueled travel boom, our caravan manufacturing client encountered a formidable obstacle: an
unprecedented doubling
of demand paired with
extended lead times.
Challenge
- Caravan demand doubled in 12 months due to COVID related increase in local travel
- Lead time crept up to 4 months
Situation
- Struggled to keep up with demand of 4 Caravans per week
- 20-30% of operators’ day was spent searching for tools and materials
- Some materials stored in up to 4 different locations
- Sub-assembly line produced at faster rate than main assembly lines, leading to huge inventory level of finished sub-assemblies and significant increase in lost and damaged sub-assemblies
Solution
Implement Visual Displays using 5S Workplace Organisation
- Marked out and labelled material storage locations
- Consolidated material locations from up to 4 down to 1
- Created a visible home for all tools
- Set out parts in assembly sequence
- Implemented visual control signal that stopped sub-assembly production if main assembly lines were already full
Before
After
Line marking and labelling of locations for tools, equipment & materials reduced time searching by operators.
Before
After
Line marked & labelled lanes for finished assembly types reduces time for next process to find and assemble into Caravan.
Before
After
Reduced time picking items in the warehouse with designated locations & labelling for all stock.
Results
75%
INCREASE
Productivity
4 → 7 Caravans a week
24%
REDUCTION
Lead Time
24% reduction
Tangble reduction in operator frustration.
