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Leverage Lean Management to Build a Highly Functioning Transmission Manufacturing Facility by Scratch

Situation

MetaExpert, Thomas, is a seasoned manufacturing expert. He was tasked with leading a transformative project for an Airbag Systems manufacturer in the automotive industry. The primary goal was to establish a lean manufacturing facility capable of producing a thousand transmissions a day. Thomas was tasked with turning an empty facility into a high-capacity transmission production plant within a tight schedule.

 

● Starting from scratch: The project involved converting an empty facility into a fully operational manufacturing plant.

● Short timeline: The team faced a challenging schedule to meet the goal of producing a thousand transmissions daily.

● Maintaining quality: Ensuring high-quality standards were met despite the rapid production pace.

Actions

  • Assembly line design: The team designed an assembly line optimized for lean manufacturing, minimizing work in process and ensuring one-piece flow.
  • Quality control: Stringent quality control measures were put in place, including thorough inspections and testing stations.
  • Procurement and logistics: Thomas and his team ensured the timely procurement of equipment and parts to avoid delays.

Results

  • On-time Delivery: The project was completed within nine months, meeting the ambitious schedule.
  • High-Quality Output: The quality control measures resulted in a low defect rate (less than 1%), reducing the need for rework and repairs.
  • Capacity Achievement: The facility successfully met the goal of producing a thousand transmissions a da

Return on Investment

The project was completed on time, a great feat, which saved budget and resources. With transmissions being shipped in working order, they saved repair costs and improved overall processes which saved time and effort for years to come.

 

Skills Needed:

● Lean manufacturing expertise

● Project management

● Quality control

 

Contract Length:

3 to 4 years

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