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Hosca are'the' lean manufacturing consultancy

Case Studies

Client :- Manufacturer of Moulded Rubber Parts, Rouen, France
Situation :- Part of a major multi-national; employing 1500 people on site. Product in question running at 35% PBIT and not improving.
Objective :- Review the process and make changes to bring the product to at least breakeven.

Proposal :- Analyse the line to establish current rate of production versus customer demand (TAKT). Establish process and working inefficiencies and determine the optimum layout and methods to improve.
Approach :- HOSCA recommended setting up a multi-discipline, multi-level team from the area and support services. The team were trained to analyse and determine best working methods themselves in order to ensure ownership and commitment to any proposed solutions.

Outcome :- The team spent 5 days reviewing and measuring various aspects of the operation including:
 
  • TAKT time
  • Process methods
  • Line Balance and Total Loss
  • Ergonomics
  • Operator flexibility
  The recommendations were accepted totally and implemented over a 30-day period.

Benefits :-
Aspect Before Target Actual
Overall PBIT
-35%
0%
+3%
Output per man-hour
20.6
28.7
27.4
Scrap
10%
10%
8.5%
Distance part travelled
37.5m
5m
5m
Space Used
295 sq.m
295 sq.m
180 sq.m
Total Directs in Area
31
17
18

Further :- The above measures were taken 6 months after the activity. Subsequent to the activity, the team progressed to implement Kanbans and reduce lineside stock by 65%. Support services were incorporated into the formed cell and are now able to react instantly to problems as part of the overall team.

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