Multifaceted Approach Resolves Production Ramp-Up Issues
How Seraph stabilised operations, eliminated bottlenecks, and accelerated a complex production ramp-up.
INDUSTRY: Automotive Manufacturing
SERVICES: Health Assessment. Logistics. Staffing Assessment. Operations.
Situation.
A wire harness manufacturer was struggling to meet the required production volumes for its automotive Tier-1 customer. To identify key bottlenecks across warehouse readiness, manpower and industrial processes, Seraph was engaged to conduct a plant assessment across their operations.
Actions.
3 key work packages were identified:
WORK PACKAGE 1
Logistics
Objective:
Defined physical space and layout needed to achieve ramp-up targets.
Deliverables:
- Developed logistic processes from receiving material to booking, inventory management, and material flow to the line.
- Ensured sequence adherence was followed.
- Moved marriage process from Plant 2 to external warehouse.
WORK PACKAGE 2
Manpower
Objective:
Evaluated current staffing and action planning.
Deliverables:
- Defined headcount requirements by area.
- Monitored hiring curve to evaluate operator skill level.
- Supported training plan
- Established training process
WORK PACKAGE 3
Industrialization
Objective:
Developed process to track safe launch, including pre-standard operating procedures (SOP) requirements.
Deliverables:
- Ensured industrialization activities for upcoming standard operating procedures (SOP).
- Tracked production schedule status, and shipment follow-up.
- PFEP calculation and validation to support ramp-up to 600 vehicles per day.
Results.
Key Improvements:
- Upstream improvements impacted key inventory metrics which protected the customer.
- Despite increased demand from OEM, days on hand (DOH) inventory improved while achieving increased performance output.
- Demonstrated leadership across the facility by strengthening shop floor management which drove higher sub-assembly output.
- Improved downtime tracking and control, driving increased OEE and output.
- Enhanced quality performance with strong problem-solving discipline.
- Facilitated knowledge transfer, through a smooth handover, enabling business sustainability.
Seraph developed visual tools to ensure WIP preparation to avoid subassembly disruptions.
Seraph mapped current state and defined future state warehouse layout. Validating PFEP calculations set a clear picture for strategy development and execution.
WORK PACKAGE 1
Logistics
- 153% increase in finished goods (FG)
- 133% increase in marriage process output over a 16-week period
- 221% increase in days on hand (DOH) on-site
- Created visualization tool: expanded from 1-day foresight covering 240 vehicles to 3-day foresight covering 945 vehicles, which positively affected finished goods and marriage process output.
WORK PACKAGE 2
Manpower
- Increased jobs per week capacity from 1,875 to 3,000
- Lean-Six Sigma Project: reduced process variation and fostered an awareness culture
- Line output enhancement: achieved increased output by minimizing downtime
- SWAT Team Formation: skills and
knowledge for on-floor operations.
WORK PACKAGE 3
Industrialization
- 38% reduction in downtime
- 56% quality increase in initial 8 weeks of project
- 25% quality increase in weeks 10 and 12 of project
- Material warehouse: created clear plan for expansion from 320 to 600 vehicles
- Seraph increased schedule attainment from 72% to 87% while the customer demand increased from 150 to 315 vehicles per day.
- Output increased by 28%.
- Downtime for subassemblies decreased 38%.
