IMEG was hired by a tier-1 automotive seat supplier to develop processes for a major model change. This customer employs 600 people across a weld plant and an assembly plant, each with an area of 110,000 ft2 and 120,000 ft2, respectively.
THE PROBLEM
Volume change’s effect on takt time
Process time changes due to new product features
Work instructions need to be updated for new model
Unknown impact on manning
Unknown impact on existing process balance
Unknown impact on existing equipment capacity
New quality requirements
THE PLAN
Develop processes and MODAPTS code from product drawings to estimate process time
Observe and document new model processes
Complete capacity analysis to determine equipment needs
Determine which processes need poka yokes based on quality requirements
Update work instructions to new process
Time study and pace rate trial builds to validate calculations
model change process development
THE RESULTS
Developed an efficient process that resulted in a successful and well executed new model launch
Developed new work instructions with poka yokes for 72 stations across 9 production lines
Identified new equipment to be implemented in order to provide necessary capacity
Manning levels and process balance were accurate and required minimal tweaking post launch
