Lean

TAYLOR MADE SYSTEMS

Hatch Assembly

About 10 years ago we created a Manufacturing Engineering group with an emphasis on continual improvements using LEAN manufacturing techniques. The team has focused on efficiency improvements, set up time reductions, cycle time improvements as well as scrap reduction. Using capital investments, Kaizen events and "5 S" techniques in multiple areas of each of our plants we have created visual pull manufacturing systems which focus on eliminating wastes.

These LEAN initiatives have produced several thousand square feet of available factory floor space and allowed new projects such as the Integrated Tower-Windshield, Ultra III hatch, Engineering design center and the CNC machining centers to be installed without adding additional structure to our factories.

As with all LEAN manufacturing operations this is a continual process for all of our manufacturing operations and we will continue to identify wastes and apply necessary resources to reduce or remove any non-value-added activity.

Following are examples of the improvements our Manufacturing Engineering group has made:


STAINLESS STEEL PRODUCTION CELL
  • 80% reduction in Work in Progress (WIP)
  • 25% reduction in factory floor space
  • Machine set up time less than 5 minutes for all machines in the cell
  • Overall cycle time (from raw material to finished goods) reduction from 14 days to 18 hours

DOOR DEPARTMENT PRODUCTION CELL
  • 50% reduction in WIP
  • 30% reduction in floor space
  • Overall cycle time reduction from 7 days to 2.5

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