Increased output and minimized wastage in the container assembly


20/07/2010
The reorganization of the container assembly was a success Mr. Peter Müller, plant manager at moll Funktionsmöbel in Gruibingen, commented the reorganization project as follows: "The involvement of SCHULER in the reorganization of the container assembly was really very valuable!"
It all started with raising the awareness of the employees. By means of the Just-in-time game consultants of SCHULER showed the participants diverse manufacturing philosophies and their impact on the manufacturing process. The main focus was set on the lead time and on the work-in-process. By minor changes from game round to game round it could be made clear which types of wastage occur more intensely when using a certain philosophy. It became obvious how wastages can slow down or impede a system. The purpose of the Just-in-time game was to evoke new ways of thinking and to prepare for the subsequent workshop.

		Reorganization workshop – employees play an active role! The workshop was moderated by consultants of SCHULER. They started with a task analysis carried out directly in the container assembly and the recording of internal routes required for the completion of a container. With a spaghetti diagram the initial situation was exposed as detailed as possible to all participants. After the analysis the team developed possible solutions for the reorganization of the assembling line with focus on minimization of wastage. This should however not mean reinventing the wheel. The design should integrate already existing resources – if necessary with minor conversions. Based on diverse drafts the final version could ultimately be created and implemented within a very short time. Successfully, as it turned out, as the output of the line could be increased by more than 20% after the conversion!

Fine tuning to progress towards optimum effectiveness

"If you don't go forwards, you go backwards. There is always something to improve!" As Peter Müller likes to say. Thereby he hits the nail right on the head. Therefore a further analysis was carried out with the involvement of SCHULER some time after the implementation of the measures agreed in the workshop.

The assembly system was once more examined with regard to improvement potential and the employees could give a feedback on the experiences they made with the new system. This time minor improvement suggestions were discussed, elaborated and promptly implemented.

And because theory is always second-best to practice, a fine tuning always makes sense. Only at or after the implementation of ideas the small crucial points become apparent which have to be tackled!
Their optimization is profitable.

The reorganization of the container assembly was a success

Mr. Peter Müller, plant manager at moll Funktionsmöbel in Gruibingen, commented the reorganization project as follows: "The involvement of SCHULER in the reorganization of the container assembly was really very valuable!"