Manufacturing Excellence Line- Efficiency Improvement Project
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This document outlines efficiency improvements made through the ME methodology at a Walmart plant. Key metrics like efficiency, production, and people ratio were measured against targets. Process flows, layouts, and balancing were analyzed. Methods were improved for several processes, increasing capacities and reducing cycle times. As a result, production increased by 200 pieces and efficiency improved by 17%. Line balancing efficiency also increased by 12%.
Manufacturing Excellence Line- Efficiency Improvement Project
- 1. EFFICIENCY IMPROVEMENT THROUGH ME METHODOLOGY Style: FG36T380 Buyer: Walmart Line: 01 Unit: Unit-2
- 2. DEFINE
- 3. DEFINE Training & Development Training with Line chief, Supervisor& Line IE about ME Methodology . After that completed simulation exercise
- 4. MEASURE
- 5. MEASURECONTINUE Category Current Target Efficiency 76% 91% Production 1000 pcs 1200 pcs People Ratio 77:5:18 79:5:16 SMV 24.3 23.3 Line Balancing 74% 86%
- 6. Category Attachment Base data Current OB Process flow chart People Ratio Capacity Graph Lay out Base data Current OB People Ratio Capacity Graph Process flow chart MEASURECONTINUE Lay out
- 7. ANALYSIS
- 8. IMPROVE Benefits: Line 1 & 2 both line production increase 200 pcs production increase 17% efficiency improved Benefits: 12% balancing efficiency improved 1. Method analysis 2. Line balancing analysis
- 10. IMPLEMENT Line Balancing Category Before After Line Balancing 74% 86%
- 12. METHOD IMPROVEMENT. Cuff Press Before After
- 13. METHOD IMPROVEMENT Cuff Attach Category Before Method Improve After Method Improve Capacity 48 pcs 59 pcs Cycle time 62 sec 51 sec Result 110 pcs/day increase
- 14. METHOD IMPROVEMENT Box & cross stitch Category Before Method Improve After Method Improve Capacity 90 pcs 125 pcs Cycle time 33 sec 24 sec Result 350 pcs/day increase
- 15. METHOD IMPROVEMENT Att. sleeve tap 2 gamble Category Before Method Improve After Method Improve Capacity 111 pcs 130 pcs Cycle time 27 sec 23 sec Result 190 pcs/day increase