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."
Lean 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.
