Class 8 Semi Truck Manufacturer

Problem:

The Class 8 Semi Truck Air Conditioning Line was experiencing excess waste and rework of finished goods, excessive redundant motion of workforce, and high inventory holing cost with low turnaround.

Solution

1. Execute Kaizen Rapid Execution Event.
2. Redesign of the production push system to a TPS JIT pull system.
3. Reduce waste, low inventory holdings, and implement single piece flow.

Results

1. 50% reclamation of shop floor space.
2. Increased Capacity
3. Elimination of finished goods rework.