Before Image of Plant Layout |
PLANT FLOOR REDESIGN
* 11% Labor Reduction One of my first projects tackled as VP Manufacturing was the redesign of our plant floor layout. The area noted as 1 in each image is mechanical assembly,2 is electronic assembly, 3 is final testing. Spaghetti chart concepts were used to assess people and product flow to eliminate waste and safety hazards from product movement. In the BEFORE image on the left, two things are apparent. First, the center section of offices clearly impedes product flow from assembly areas at each end of the building to meet in final test. Second, the electronic assembly area is small, cramped and overcrowded with work stations. To improve product quality and flow, I undertook a capital project to remove the center offices and build new technician offices at the end of the building. The project plan was developed, approved and executed within a 3 month time frame. Prep work was completed with protection of in-process electronic components, and no contracts were impacted in either quality or schedule. Revenue was not impacted, as the primary demolition work was completed during a planned holiday shutdown and full production resumed 3 days after the shutdown. |
After Image of Plant Layout |