The Company is one of the largest designers and manufacturers of city buses in North America. In 2006, its production capacity was increased by 66% and on work shift was added.  This rapid growth needed organisation change at several level. GCC was awarded two major contracts to help the company overcome achieve its goals.

Implementing a Kanban system to streamline deliveries between supplier and production line

MAJOR PROJECT MILESTONES

  • Development and close tracking of pilot project on a single workstation
  • Establish full scale deployment plan
  • Identify workstations to be upgraded and set up timeline for upgrade work
  • Establish safety stock level per bin
  • Plant-wide deployment of Kanban system
  • Follow-up and fine tuning of parameters

RESULTS

This Kanban system greatly reduced shortages on the production line
— Logistics and operation manager.
  • Reduced handling time at reception area by replacing manual identification to computerised solution
  • Reduced lead time for production parts
  • Reduced inventory held on the line
  • Eliminated the need for logistics department to order recurring items
  • Streamlined billing

General logistics improvement

MAJOR PROJECT MILESTONES

  • Time study of inventory clerks’ activities and movement
  • Establish standard times of clerks’ activity per item family and storage locations
  • Value stream mapping of reception area and material handling
  • Work sequence establish to streamline inventory clerk’s activities
  • Further deployment of the Kanban system
  • Warehouse layout improvement

RESULTS

  • 50% reduction in warehouse space needed
  • Further reduction in parts shortage on the production line
  • Significant time saving in internal material handling