IMEG was hired by a water filtration system manufacturer to study, analyze, and develop process and quality documentation for manufacturing processes in preparation for a facility move.
THE PROBLEM
No work instructions for process builds
Excessive time required for operator training
Increased risk of process failures
No quality documentation for control or inspection processes
Lack of understanding of process times
THE PLAN
Observed and took video recordings for each assembly and packaging process
Conducted video-based time studies on the current process
Calculated run rates and process times for current and future state
Identified existing quality concerns
THE RESULTS
Participated in 3 Kaizen events to narrow in assembly process balance while reducing operator headcount
Created over 100 work instructions
Created PFMEAs, control plans PIPs, part inspections, final assembly inspections, and packaging inspections for all 35 finished assemblies and their respective components
