Initial situation:
- Tier-1 supplier facing inefficient production of metal and plastic components.
- Discrepancy between planned system lead times and actual shopfloor times.
- Lack of continuous improvement processes causing productivity losses.
Our approach:
- Conducted detailed REFA time studies on 10 representative products.
- Identified process inefficiencies, bottlenecks, and standardization gaps.
- Designed improvement measures, including low-cost automation and layout adjustments.
- Trained local teams on industrial engineering methods and continuous improvement.
- Implemented KPI-based tracking to monitor and sustain improvements.
Results:
- ~155 sec/part reduction in 8 of 10 products, achieving ~24% average efficiency gain.
- Top product improved by 36%, saving ~1,865 working hours/year.
- Reduced unnecessary quality checks and material movements.
- Strengthened long-term process improvement and performance bonus systems.
Conclusion:
Significant productivity uplift achieved through structured analysis and targeted optimization, securing sustainable competitive advantages.
