Production Output Growth through Process Reengineering website
Case Study
Production Output Growth through Process Reengineering
With rising demand for key calibres and limited capacity expansion options, the client needed to increase output without increasing headcount or machinery. Key challenges included bottlenecks in loading and inspection, shift inefficiencies, high WIP, and delayed order fulfilment.
Optimized existing operations to boost production output without adding new machinery or manpower, addressing capacity constraints effectively.
Resolved key bottlenecks in loading and inspection stages, improving flow efficiency and reducing cycle times.
Streamlined workflows and shift utilization, resulting in lower work-in-progress levels and faster order fulfilment.
Project Info
Confidential
Operations Lead / Continuous Improvement Advisor
Operational Efficiency & Process Reengineering
Approach & Execution
Phase 1: Baseline Assessment
Conducted OEE benchmarking and tracked MTTR/MTBF across key assets.
Phase 2: Line Rebalancing & Scheduling Redesign
Operator reallocation, kanban boards, workstation redesign, FIFO flow
Phase 3: Operator Empowerment & KPI Feedback
Training on takt flow, daily briefings, tier boards, and pacing tools
Tools & Frameworks
- Time-Motion Analysis, Lean Layout Design
- OEE, Takt Time, Visual Management
- Theory of Constraints (TOC)
Workforce Engagement
Daily shift huddles and performance boards
Operator input on layout redesign
Green/red KPI flags and feedback loop
Results
40% increase in daily output across lines
OTIF improved from 76% to 98%
50% reduction in changeover waste
Improved space utilization and WIP consolidation
Repeatable model for future expansions