Decreasing Downtime and Increasing Jobs Per Hour of a Tier One Automotive Parts Suppler

RPM focused on seven actionable categories across the facility:

Pre-build:

• Installed a countdown clock for pacing all operations

Final Inspection:

• Emphasis on meeting OEM quality inspection criteria

• Implemented a paint "touch-up" repair process

End of Line (EOL):

• Added resources for load/unload

• Installed stock product in the repair station

• Added buffing station containment until paint issues could be resolved

• Tracked machine downtime and implemented permanent corrective action for the top five issues

• Implemented a spare parts program

Organizational:

• Hired workforce to 85% of peak volume requirement (Ops and Logistics)

• Trained new-hires to Level 3

• Filled open team lead positions

• Developed team lead routines and leader standard work

• Installed tracking screen for shipping status visual management

• Implemented an effective data collection methodology to improve the finer granularity of downtime data for analysis

• Installed production boards with hourly and shift targets

• Initiated an S&OP process to stabilize planning, scheduling, and production

• Filled gaps in management experience and capability

Production stabilization:

• Used granular downtime data to create Pareto charts to identify high-impact root causes

• Revised work instructions for the methods required to achieve the required JPH

• Implemented flow racks for material storage line side

• Studied processes and identified opportunities for machine and human cycle time reduction

• Defined KPIs, implemented visual management, and performed leader standard work to drive operations toward JPH and quality targets

• Identified shortcomings in management competency and proposed solutions

Kitting:

• Implemented a fast-track kitting process for recovery when something was missed

• Installed a dedicated rebuild station on the line

• Installed tracking screen for visual management of line synchronization

• Implemented "water spider" role to deliver finished racks and return empty racks to kitting

Logistics:

• Identified critical parts and installed safety stock

• Added stock of critical parts line side

Quality:

• Installed a "Quality Wall" in paint to eliminate defect escapes to the line

• Stored painted safety stock of high runners line side

• Relocated incoming inspection to catch defects earlier