Optimizing the Production of a Client Product Using Lean Manufacturing
About the Project
Project date:
2025
Industry:
Recreational
Processes used:
LRTM
Challenges
Triple the daily production output of a client's product consisting of several varied parts.
- Identify new bottlenecks caused by tripled production
- Maintain production within the same allocated floor space
- Implement changes within 3 months without compromising committed deliverables to the client
- Recruit and train several new employees
Internal Process Optimization
Lean Manufacturing
Organization and Flow
Implement 5S to improve workstation organization and analyze bottlenecks to optimize production flow.
Performance Management
We introduced visual management tools for critical production information and implemented daily KPI tracking to monitor performance.
Waste Reduction
We reviewed manufacturing methods to eliminate non-value-added activities and used Pareto analysis to identify the primary causes of defects and reduce non-quality
Results
Through Lean manufacturing tools, daily production was successfully tripled in less than three months.
5S Implementation Enabled:
- Optimization of the floor space used by each workstation
- Use of freed-up space to double the number of workstations at critical stages
- Reduced travel distances and improved workspace efficiency
Production flow analysis enabled:
- Implementation of a circular production flow, offering the ability to centralize fixed production equipment and allow access from all workstations
Visual management implementation enabled:
- Facilitating communication and information sharing across production teams
- Improving workstations to facilitate and accelerate the onboarding of new employees
KPI Tracking and Pareto Analysis Enabled:
- More proactive management on performance gaps
Manufacturing Method Improvements Enabled:
- Elimination of multiple sources of waste and reduction of cycle times
- Earlier detection of quality issues
- 50% increase in first-pass yield
