Pull flow in the manufacture of automotive components
8 hours ago
1 min read
Context
Implementation of a pull system to reduce lead time and increase productivity
Automotive components industry
Problem
Low productivity
Too much work in process
Mix-ups and errors in materials management
No FIFO
Urgent deliveries
Approach
Process mapping (VSM) from end to end
Defining and measuring indicators:
Muda elimination through workshops
Improving flow on assembly lines
Standardized replenishment (supermarket and internal milk-run)
Pull flow for finished products (heijunka and information flow to the lines)
Implementation of external milk runs
Results
Assembly Productivity: +40%
Lead Time: -50%
Elimination of urgent shipments
Overall productivity: + 25%