Devizes Fine Kitchens
Design and Manufacturers of high specification, bespoke solid wood kitchens. MAS asked to help to reduce lead-time and improve on-time delivery, and increase capacity.
Background
Design and Manufacturers of high specification, bespoke solid wood kitchens, supplying specialist design houses or direct to end user. Facilities consist of labour intensive traditional cabinet making skills and machinery. Separated into five generic departments Cut, Mould, Assemble, Finish & Pack/Despatch.
Scope
Reduce lead-time and Improve on-time delivery.
Increase capacity without increase in labour. (Reduce Level of Non Value Added)
Investigate reason for high level of rework cost (£50K/Year)
Improve staff Involvement, Awareness of Non Value Added and Problem solving skills.
Improve order prioritizing and status/progress information through process.
Method
Value Stream Mapped Kitchen door manufacture for major customer
Conducted 1 day Waste Awareness - Factory Simulation workshop
Facilitated "Waste Spotting" workshop with section leaders.
Options and Recommendations
Identified Lack order status reporting and information, no defined communication process. Quantified Process steps, Cycle-times, Lead-time, scrap, inventory, distances product travelled and determined Value Added and Non Value added activities throughout the process.
Detailed Workplace organisation programme. Layout changes and defined material location areas.
Results
- Introduced production review meeting with section leaders improving communications and prioritization of resources.
- Reorganise material storage area releasing 15% additional floor space and improving housekeeping/Health & Safety.
- Reduction in cost of painted door manufacturing by 80% due to elimination of 60% of process steps.
- Identified visual order status & machine/operation loading system by developing defined areas for materials.
- Trained section leaders in Waste/Non Value Added activities identification.
- Brainstormed further ideas to systematically, reduce, combine or eliminate Waste/Non Value Added activities.
Further Actions
Client reviewing level of inventory (Non/Slow moving stock), Inappropriate processes (Redundant Machines) and developing improvement program to deliver further identified ideas.
Client to investigate the implementation of Computer Aided Design to speed up changes and reduce design errors. MAS continuing to Audit.
Customer Feedback
Valuable advice and assistance focused on improving the business.
