An automotive supplier using the Toyota Production System (TPS), aimed to balance material flow, minimize assembly line downtime, and seamlessly meet OEM demands. The strategic goal was to implement efficient material management solutions to enhance operational resilience and sustain consistent productivity.
Approach
- Assessed production schedules, material cycle times, and off-site vendor supply chains to identify bottlenecks.
- Modified re-order points for inventory pull (kanban system) to improve material availability and reduce shortages.
- Implemented ranked inventory management for seamless material transitions, minimizing downtime.
- Optimized material handling routes, dividing responsibility across two team members to improve efficiency and ensure continuous line support.
Results
- Reduced Downtime: Material-related downtime was reduced to under 30 minutes in the first week, with no further issues observed thereafter.
- Improved Inventory Control: Transition points between ranked materials became more visible and manageable for assembly technicians, preventing disruptions.
- Sustained Production Flow: Adjusted kanban re-order points ensured a steady supply of materials, effectively preventing shortages on the line.
- OEM Demand Compliance: client met all OEM demand requirements and schedule changes without interruption, enhancing customer satisfaction and reinforcing production reliability.
Segment: CPG / Food & Beverage · Services: operational-excellence, supply-chain-planning