Lean Line Design Project - Blue Cold Case Study

Lean Line Design for Industrial Cooling Unit Manufacturer

 

Background

The client has vast industrial experience in the business of manufacturing quality range of Condensing Units, Industrial Unit Cooler, Slimline Evaporator and many more. Also, they have adopted strict quality control measures, which enable them to deliver only best and quality tested products into the market.

 

Challenges

•The handling of materials has been identified as a critical area of concern, characterized by inefficiencies both between and within the processes. This issue encompasses the movement and management of materials, revealing notable shortcomings in the current operational setup. It was imperative that we address this challenge promptly to streamline the flow of materials, minimize delays, and ultimately enhance overall productivity.

•One of the other challenges we observe the absence of dedicated storage space for raw materials (RM). This created a significant logistical hurdle within the operations. The lack of specific storage for RM led to disorganization, making it difficult to locate and access materials promptly and efficiently.

•A notable bottleneck in the operations was the prolonged waiting time for Equipment On Time (EOT) at several stations. This delay significantly hindered the workflow efficiency and led to idle periods for the workforce and often resulted in a backlog of tasks.

•Another major issue it was the unbalanced distribution of capacity among the machines. This discrepancy created a significant challenge in maintaining a smooth and efficient workflow. Some machines were underutilized while others were overburdened, leading to inefficiencies and potential delays in production

 

What We Did:
Lean Line Design for an output of 8 Coils per shift

To design a manufacturing facility capable of producing 8 coils per shift, we undertook a task that necessitated meticulous study and detailed design of man, machine, material placement, and process flow. Our approach followed a systematic and collaborative step-by-step implementation. Initially, we conducted a thorough analysis of the production requirements and constraints. This included an assessment of the available space, machinery capabilities, and workforce capacity. By understanding these parameters, we were able to establish the feasibility of achieving the target output.

With this foundational knowledge, we meticulously designed the layout of the facility, paying close attention to the placement of man, machine, and materials. This involved optimizing the spatial arrangement to minimize unnecessary movement and maximize workflow efficiency. Additionally, we conducted a detailed study of the production process flow. This included analysing each step, from raw material input to final coil output, to identify potential bottlenecks or inefficiencies. By mapping out the entire process, we were able to implement improvements that streamlined production and enhanced overall productivity.
Throughout the implementation, we emphasized a holistic approach that integrated the needs of man, machine, and material. This ensured that each element of the manufacturing process was seamlessly integrated into the facility design, resulting in a cohesive and efficient workflow.

In summary, project entailed the comprehensive design of a manufacturing facility geared towards achieving an output of 8 coils per shift. This involved a meticulous study of production requirements, a collaborative effort to optimize facility layout, and a detailed analysis of process flow. By harmonizing man, machine, and material placement, we created a facility primed for high productivity and efficiency.

 

Establish a clear layout for production and storage areas

Our endeavour focused on establishing a well-defined layout for both production and storage areas, a crucial step towards ensuring clarity and efficiency in the operational setup. This initiative was executed through a systematic and collaborative approach, following several key steps.

Initially, we conducted a thorough assessment of existing production and storage spaces. This involved evaluating the available square footage, understanding the workflow patterns, and considering factors such as accessibility and safety protocols. By gaining a comprehensive understanding of the space constraints and operational needs, we were able to formulate a clear plan for layout optimization, taking into account the specific requirements of both production and storage areas. This involved reorganizing workstations, machinery placement, and material storage solutions to create an efficient and streamlined layout.

Throughout the implementation, we prioritized to create a layout that not only maximized space utilization but also facilitated smooth and efficient operations. Furthermore, we conducted thorough training sessions to familiarize our workforce with the new layout and operational setup. This ensured that every team member was well-equipped to navigate and utilize the space effectively, contributing to improved productivity and overall operational efficiency.

 

Efficient Material storage methods & material handling system

we focused on enhancing inventory management through the implementation of efficient material storage methods & material handling system. This involved managing Work-In-Progress (WIP) with 36 coils and Finished Goods (FG) with 128 coils. The execution followed a systematic and collaborative approach, with several key steps.

To begin, we conducted a comprehensive assessment of the inventory management needs. This included evaluating the volume and nature of both WIP and FG coils, as well as understanding the flow of materials throughout the production process. This crucial step allowed us to determine the most appropriate storage methods for each stage.

Next, was pivotal in selecting and implementing the most efficient storage methods. These included rack systems (Heavy duty racks, cantilever racks), designated storage areas, and WIP trolleys to the specific characteristics of WIP and FG coils.

Simultaneously, we integrated a highly efficient material handling system. This system was designed to seamlessly manage materials as they transitioned between different stages of the production process. It involved the strategic placement of handling equipment, such as JIB cranes, EOT cranes as well as the WIP coil tables to ensure accurate and timely movement of coils.

In summary, our project encompassed the implementation of efficient material storage methods to optimize inventory management for both WIP and FG coils. This was achieved through a detailed assessment of inventory needs, the collaboration of a specialized team, the integration of a highly efficient material handling system. The result was an enhanced operational setup that significantly improved inventory management and overall workflow efficiency.

 

Balanced distribution of capacity among the machines

Achieving a balanced distribution of capacity among the machines was a pivotal goal of our project. This objective was pursued through a systematic and collaborative step-by-step implementation.

Our journey commenced with a comprehensive evaluation of our production process. This involved a detailed assessment of each machine’s workload, output, and operational efficiency. Through this analysis, we gained valuable insights into the existing discrepancies in capacity distribution Next, we collectively devised a plan to redistribute & rearrange the capacity among the machines, ensuring that each one operated at an optimal capacity. This data was crucial in fine-tuning the distribution of capacity, as it allowed us to make data-driven adjustments to workload allocation.

By adhering to this systematic and collaborative approach, we successfully achieved a balanced distribution of capacity among the machines. This initiative not only improved productivity but also contributed to a more streamlined and efficient production process. It exemplified our commitment to continuous improvement and operational excellence.

 

Sustained Change – Our Journey

Our journey towards sustained change encompassed a comprehensive approach to Lean Line Design, aiming for an output of 8 coils per shift. This involved several strategic initiatives. First, we focused on establishing a clear and optimized layout for both production and storage areas. This began with a thorough assessment of existing space, considering workflow patterns, accessibility, and safety measures. With this foundational understanding, we redesign the layout, ensuring that it maximized efficiency and minimized unnecessary movement.

Simultaneously, we tackled the challenge of efficient material storage. By implementing a range of storage methods tailored to the specific needs – including Work-In-Progress (WIP) with 36 Coils and Finished Goods (FG) with 128 Coils – we optimized the inventory management. This step involved selecting and configuring rack systems, designated storage areas, and effective tracking systems to maintain control and accessibility over materials.
To complement enhanced storage methods, we integrated a highly efficient material handling system. This system facilitated seamless movement of materials between different stages of the production process. This was achieved through the strategic placement of handling equipment, including JIB crane & EOT crane for accuracy and efficiency.

By following this systematic and collaborative approach, we successfully achieved sustained change in the operations. This involved Lean Line Design for an output of 8 coils per shift, establishing clear layouts, implementing efficient material storage and handling methods, and achieving a balanced distribution of capacity among machines. These collective efforts significantly enhanced productivity and operational efficiency, exemplifying our commitment to continuous improvement and excellence.

 

Key results

• Productivity increased by 20% by reduction of waiting time.
• Reduction in EOT waiting time up to 2 Hrs
• Safe and easy material handling between and within the processes.
• Lean Line Design for an output of 8 coils per shift