IMPACT & BENEFITS

IMPACT & BENEFITSMATERIALS MANAGEMENT STORAGE AND RETRIEVAL SYSTEM

ADVANCED KAIZEN IN AUTOMOTIVE MANUFACTERING : Lean Sensei International has extensive and intimate knowledge of the automotive industry. Our founder and President was the first bilingual engineer hired by a General Motors plant in Canada. With over 20 years of considerable experience in manufacturing and automotive industries, our Lean Coaches have assisted clients in a wide variety of automotive kaizen projects. LSI has worked in this fast-paced industry to help our clients achieve major milestones and address challenges such as reducing defects, cycle times, down time, supply chain issues, and improving delivery times and improving overall quality. LSI’s unique approach trains organizations in Lean Thinking methodologies, with a distinctive Japanese style, firmly rooted in the Toyota Way. Below are two Kaizen examples from a global automotive company Lean Sensei worked with previously.

LEAN IN AUTOMOTIVE INDUSTRY

CHALLENGE: Meeting on-time delivery of highly customized products in a mid-volume automotive plant

KAIZEN AREA: Eliminate defects and errors to improve overall quality at the vehicle final assembly line

CHALLENGE: Critical parts and materials not delivered at the right time in the right amount to the final assembly line

KAIZEN AREA: Materials management storage and retrieval system that delivers parts, components and materials to the production assembly process

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ON-TIME DELIVERY

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SOLUTIONS: In collaboration with suppliers, engineers and team leaders from the assembly line and quality assurance areas, LSI helped the client uncover root causes to address defect and rework issues. Using Lean methodology, such as value stream mapping, root cause analysis, value graphs, we identified solutions to these problems. Lean Sensei coached team members to problem solve, identify key opportunities and strategically implement solutions.

Results showed a 20% reduction in the number of defects and errors leading to substantial cost savings.

SOLUTIONS: By working closely with teams in the gemba and team leaders on the floor, LSI identified root cause factors to problems that were previously assumed to be irrelevant. By systematically examining processes more carefully from start to end, we identified bottlenecks and waste in the form of:

• Labelling defects from suppliers• Defective sensors in automated systems• System logic errors

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AUTOMOTIVE CASE STUDY LEANSENSEI.COM® | ALL RIGHTS RESERVED © | VERSION: 12/19/2018

INDUSTRY KAIZEN CHALLENGES

KAIZEN GENERATED

20% ERRORS

REDUCTION