ABSTRACT
This chapter covers the work that was done to make the enclosure assembly line at Global Grader Company (GGC) a much more efficient Lean system. The team spent several months analyzing the current line configuration and
CONTENTS
Introduction ......................................................................................................... 291 Project Overview ................................................................................................. 292 Define .................................................................................................................... 292 Problem Statement .............................................................................................. 293 Problem Objective, Goals, and Requirements................................................. 293 Project Boundaries .............................................................................................. 294 Project Team ......................................................................................................... 295 Project Plan ........................................................................................................... 295 Lean Metrics Defined.......................................................................................... 295 Measure ................................................................................................................ 296 Process Baseline ................................................................................................... 297 Current State VSM .............................................................................................. 298 Analyze ................................................................................................................. 298 Process Gaps and Sources of Variation ............................................................ 299 Prioritize Improvement Opportunities ............................................................300 Cause and Effect .................................................................................................. 301 Statistical and Graphical Analysis ....................................................................302 Improve ................................................................................................................303 Solution Implementation Plan ..........................................................................308 Cost/Benefit Analysis.........................................................................................308 Control ..................................................................................................................309 Dashboards .......................................................................................................... 310 Mistake Proofing ................................................................................................. 311 Standard Work ..................................................................................................... 313 Results ................................................................................................................... 313
then went through a process to optimize and improve the line efficiency, allowing for a reduction of waste, unneeded labor, idle time, and the space required to produce the enclosure. This case study will detail the process that the team went through in obtaining these results.
