Successful Manufacturing Using Lean Methodology

Abstract

Johnson Electric Coil Company identified the need for greater efficiency in its heavy product manufacturing work area. The purpose of this study was to analyze and improve operational efficiencies with the goal of designing a workspace that optimized labor, improved response time, and enhanced profitability. Informed by the literature of lean manufacturing and using the concepts and tools derived from the Toyota Production System, the company improved its quality, minimized non-value-added activities, standardized processes, and increased efficiency. The initial step involved a kaizen event to draw a value stream map to identify non-value- and value-added activities within the manufacturing process. Once non-value-added steps were identified, a plan to reduce waste was established. Analysis of quality data revealed two high-incidence quality issues, which drove the team to develop and implement two poka-yoke mechanisms within the new work area. Construction of a product matrix, spaghetti diagram, and future value stream map set the direction for completion of a new floor layout. Finally, building 5S events and audits into operations was recommended, to ensure process standardization and continuous improvement. Ultimately, the objectives of the study were met, and the goal to improve efficiencies in Johnson Electric Coil Company’s heavy manufacturing area was achieved.