The Scenario
Our Client manufactures some of the most recognisable board games in the world. As such, they place a major emphasis on their responsiveness to their customer base. Working within short lead times to react to market demands, the unpredictable nature of output from the factory was a cause of concern. WBS Group were tasked with reviewing the current state, understanding the reasons for the productivity issues and recommending potential improvements.
The Work
In order to gain a thorough understanding of the business issues, WBS Group performed an intense Company Assessment, focussing on all areas of the business that impacted on the ability of general assembly area to meet production demands. In effect this meant a complete supply chain review from forecast through to shipment of product.
The Assessment Findings
Several areas were found to affect productivity and were highlighted by the assessment. These included:
- No focus on reduction of changeover times despite the fact that the business was experiencing increasing numbers of changeovers
- Multiple handling of components with no value being added
- Inaccurate data recording leading to difficulties in problem resolution
- Overall product awareness poor for some operators
- Inconsistent methods of operating production lines resulting in confusion in completing production runs
- Planning at family product level as opposed to SKU level
- Conflicting measures and targets on functions and departments
| Recommendations |
Benefits |
| Reduction of Assembly Line
Changeovers |
Increased availability of Assembly Line
of 142mins per week = 249,000 extra
parts per annum
|
| Reduction of Assembly Line
Changeovers |
Increase in Output of Assembly Lines
Increase in output of over 10% of
existing output = 607,000 extra parts
per annum.
Elimination of 1 existing assembly line |
| Introduction of Differing Demand
Fulfilment Models |
Reduction in changeovers = 468,000
extra part finished components per
month in upstream activities |
| Reduction of Assembly Line
Changeovers |
Increase in Output of Assembly Lines
Increase in output of over 10% of
existing output = 607,000 extra parts
per annum.
Elimination of 1 existing assembly line |
| Improved Displays of Line Output &
Status |
Reduces errors in cycle counts and
provides early warning of forthcoming
changeover. |
| High Level Redesign of Assembly
area |
Creation of material staging areas
adjacent to point of use thus reducing
product handling & distance travelled.
Elimination of potential Health & Safety
issues in working areas |
The WBS Group were further commissioned to provide a detailed redesign of the factory
layout.