The customer detected production stops and inefficiencies in the departments, with utilization ratios of some machines too low. Therefore, an organizational intervention was necessary to identify performance improvement measures.
- Job and production time analysis, including through ad hoc videos on assembly, testing and painting lines;
- Production of time sheets and methods-time measurement;
- Proposals for improvement of both workstations and line layout, with cost/benefit quantification;
- Production of AutoCAD drawings with proposals for modifications of existing equipment or devising new solutions.
The changes made increased the utilization factor of coating equipment from 40% to 62%; besides, a 20% saving in cycle time was achieved.