Case Study 2-06583
When there’s not enough time in the day
So much to do and so little time. Sometimes, you do need an extra set
of hands to get the job done on time. IET provided some “extra hands”
with shop floor expertise to help its client meet a deadline with
important financial ramifications.
An automotive OEM assembly plant that was just about ready to ramp-up
production of a newly introduced model.
In six weeks, the plant would be calling back workers on its second shift to
begin the production ramp-up. Given the tremendous cost pressures in this
business, the management team wanted only the minimum number of people
necessary to assemble the new vehicle. The only way to do so was to use
accurate labor standards to create a balanced work load. The plant industrial
engineers had so much work on their plates that they needed someone else to
develop standards using the approved pre-determined time study method
MODAPTS. Within six weeks, 250 work stations needed to have standard work
defined with accurate predicted times.
IET assigned four engineers to the task because the timeline was so short.
Working as a team, these engineers took responsibility for separate work
stations, yet collaborated with one another to take advantage of each person’s
unique strengths and ensure consistency. They reviewed progress daily with the
client to stay on-target and resolve problems that could delay the effort. IET
engineers recorded their results in the client’s business system that maintained
standard work assignments so it would be ready to use.
At the end of the project, the client had information that they could use to
determine optimal manning levels for varied levels of production for each of the
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