Design of production and logistics processes for a new production line of an existing product
An additional production site is required for a successful product that is already in production at another site. Many would simply opt for a copy-and-paste approach to this challenge. A large and successful automotive supplier was not satisfied with this, because they saw a rare opportunity not only to apply new principles and approaches, but also to test their effectiveness against the benchmark of the “old” plant.
This was the right moment to bring BLSG on board to help develop a production system that was as efficient and lean as possible.
Industry
Automotive Supplier
Challenge
An additional production site is required for a successful product that is already in production at another site
Development of a lean and efficient production system as well as the improvement of central LEAN key figures
Solution
Basic training for the interdisciplinary project team:
- Value stream design workshop
- Development of a prototype image of the production line
- Detailed target value stream and target layout
- Approaches to production control: new interlinking options and lean workplace design for efficient material provision
Verification of ideas with the help of cardboard engineering: setting up planned workstations using cardboard boxes in order to simulate the workflow based on a quasi-real example
Monitoring the configured production control by simulating different scenarios
Result
More efficient, flexible production and plant concept with a lean production control concept and a matching, space-efficient layout