Case Studies
Vacuum Cleaner Manufacturer - 2005
Fri, Nov 20th 2009
Client Profile
A Global Branded Manufacturer of Vacuum Cleaners / High Technology FMCG products with an international supply chain based mainly in the Far EastBrief / Assignment
Conduct a full Value Stream Mapping Exercise on the Malaysian final assembly line for one of the most successful products in order to develop and implement a ‘future state’ that would significantly improve output and reduce labour costsDelivered Benefits & Results
Reduced non value adding activities by 32%, reduced labour costs by 37% & increased output by 15% through the implementation of the following:
- Improved access to the line for assembly operators by redesigning the workstations in order to ensure full visibility of the flow of goods from start to completion
- Redesigned specific bottleneck workstations in order to create a better line balance / ability to meet Takt
- Proposed specific minor component design changes for simplification of assembly at key points in the value chain
- Poke yoke process introduced at a key stage in the value chain to eliminate downstream disruption
- Resized Kanbans correctly and improved supplier line side delivery process
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