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Streamlining Production Processes for Efficient Operations in Batch Production Setting

This case study discusses the challenges faced in a batch production setting, such as mismatch between sales and production, overloaded workers, excessive inventory, and wastes. Round 1 debrief highlights issues with takt time, table orientation, and information delivery. In Round 2, improvements were made to processes, including sub-division of work, implementing a pull system, and creating a supermarket.

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Streamlining Production Processes for Efficient Operations in Batch Production Setting

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  1. Round 1 Debrief - PM • Mismatch between sales & production • Fold Op2 workers overloaded • Excessive inventory in places • Wastes: kiter, excessive material handling, • Takt Time is 15 sec/boat • Reorient tables? • Supervisor delivered information/schedules • Eliminate production schedule? => next time

  2. Round 2 Changes - PM

  3. Round 2 Debrief - PM • White and blue fold had different processessub-division of work was more efficient=> continuous flow • Batch size? • Oven could cure different colors at once • Implement ‘pull system’ => create kanban • Make supermarket where continuous flow is not possible (aka upstream of oven-at end of folding & downstream of oven – start of inspection)

  4. Round 2 Changes - PM

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