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Case Study

Building a Continuous Flow Forging Factory in Asia

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An Automotive Tier 1 Supplier needed additional capacity in Asia.  Rob was selected to lead the project.  He was chosen for his ability to manage large projects, his strong knowledge of Toyota Production System, and his mentoring skills to develop the new plant manager.  Rob used the Lean Enterprise workbooks to help the new plant leaders learn Lean skills in Value Stream Mapping and Creating Visual Flow.  The new leaders were closely linked to designing the flow from billet cutting to warm forging to cold sizing with minimal inventory and continuos flow.  Rob led the team in site selection, specifying the equipment and scheduling the factory build.  The team worked very closely with Rob to overcome the challanges and deliver the project ahead of schedule and under budget.

The project included improving the existing forging operation.  Rob helped the local leadership learn SMED skills, including putting parts in a set up wheel to minimize changeovers and run at Takt time. One part of the project focused on making all tooling set up external to reduce change overs from 4 hours to less than 1 hour, which was critical to meet Takt time.

The Problem

Exisiting Change Over Times unable to meet Takt Time

Existing Team did not have Project Management experience

The new workshop must be a global forging center of excellence

Our Solutions

Reduced Change Over Time in existing press by over 75%.

MS Project and weekly team meetings used to keep all phases of the project on track. Project completed under budget by 8% and ahead of schedule by 6 months.

The new layout used conveyors to transport Work In Process between processess. Total Productive Maintenance was implemented to ensure equipment reliablility. The forgining plant operated 24/7 reaching peak output in 6 months.

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