Problems: Campus layout
at this successful foundry was becoming an increasingly important
issue with every step made toward creating a Lean environment.
Quite literally dozens of people would make a (4) to (8) block
trip, depending on the location of their work centers, to a
building housing the NDT (non-destructive testing) equipment
several times each day. Parts were being processed in buildings
several blocks away then transported via carts, trucks, or
forklifts to NDT for further processing. Generally, parts would
be tested in NDT, then returned to the original building for
additional processing. Certain parts would repeat this cycle
several times. Lean Solutions: Recognizing the importance
of locating the NDT area near its internal feeders, we found
space that would be centrally positioned and sufficient to meet
the needs of the NDT area. After considerable re-layout,
streamlining of equipment, and workflow improvements, the new NDT
location used only about 1/3 (one third) of the space used in the
earlier layout. Additionally, we incorporated a lab area that was
previously located adjacent to the old NDT facility, and a
shipping function for immediate packing & shipping of
completed products. We redesigned the x-ray processing booth to
accommodate the improved workflow, and KanBans were established
between NDT and their several "Internal Suppliers." Impact/Results: Dozens of lost
production hours were saved on a daily basis. Time that was spent
transporting products is now spent processing them. Communication
and feedback between "Internal Suppliers" and
"Internal Customers" was significantly improved. Defects caused
through packing and transporting parts were almost completely
eliminated. The unneeded and distant building that formerly
housed NDT was leased-out to further generate revenues. Very conservative
estimates value this improvement at more than $2 million
annually.
