Task: To form a manufacturing cell and ramp up production to approximately 2x the current maximum output capability in order to match Customer requirements on-time-in-full.

Approach:  A small multifunctional project team was formed from a selection of operators and cell support staff to develop the Concept Design for the new output levels in a 1-week breakthrough activity - to present-back to the senior team and the workforce at the Friday shift change!  The main steps were as follows:

• Train the team in the essential tools from the Lean Toolkit
• Agree the approach and deliverables for the week
• Gather the data from the existing process steps; process times (man & m/c) equipment & tooling facility requirements, exiting performance data, safety and quality procedures, Customer & Supplier Logistics.
• Develop the TAKT time as the target drum beat
• Develop operational scenarios within this drum-beat to optimise work-balancing,
• Layout equipment in the most comfortable and safe manner to suit the proposed manning scenarios, and enable effective materials input and output to the operational cell
• Review all aspects of the Operating Concept to ensure it is robust and the team are confident in their proposals: the Layout, Manpower plans, Cycle times Vs Takt, Materials 'in' and 'out' etc.  NOTE This step in the process is the 'reality check' and involved a wider review amongst other key stakeholders
• Finalise Proposals and Layout Drawings
• Create the presentation for ALL Stakeholders, the seniors and the factory at the same session in a convenient area of the factory (~120 people)
• Finalise the Concept Design following inputs received and create a plan for the changes

Benefits:

Smooth and successful ramp-up to meet the challenging output requirements, achieved within 2 months, to the delight of the senior team and Customer alike.