Project Brief

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Visual Management System

A high volume Tier 1 automotive supplier was experiencing lower than expected productivity levels on an assembly line. In support of the client's continuing Lean manufacturing and Operations Excellence initiatives, Systemental was asked to provide management tools to for visual minute-by-minute and hour-by-hour assembly line production pacing. The system would need to provide the line operators and supervisors immediate feedback about the pace of product advancing through the line.

The custom designed solution created by Systemental now enables front line leadership to apply the right resources at the right time to diagnose and improve productivity by providing real time visibility of line throughput vs. targets. The solution is so effective it has been rolled out to additional assembly lines at three other locations in the US and Mexico.

Summary

Client	Tier 1 Automotive Manufacturer
Problem	Real time visibility of assembly production throughput vs. targets was needed to ensure Lean manufacturing and operational performance goals are obtained.
Solution	Systemental partnered with the client's engineering, production and IT departments to design, develop, and deliver a solution including: simple red, yellow, green indicators actual pace vs. target pace display of BOM and special instructions for current and upcoming product runs synchronization of assembly controls with the end-of-line test equipment to facilitate changeovers bar code scanning data entry to prevent errors and save time
Results	The system proved successful and has become the standard for similar assembly lines across the U.S. and Mexico leading to hundreds of thousands in annual savings.
Contact	Toll free 866-434-2040