CONTEXT

The company is an important repair and remanufacturing railway company. To contribute to the operational efficiency optimization and increase, the organization must standardize its processes and make them more efficient.

PROJECT STEPS

Define phase

  1. Define the project scope (constraints and limits) and do a meeting with all stakeholders;
  2. Establish the project chart (goals, scope and stakeholders clearly defined); 
  3. Define project deliverables;
  4. Plant tour to establish what the operational management current picture is. 

Measure phase

  1. Identify value-added and non-value added activities by doing a work sampling study; 
  2. Lead workshops to evaluate the interactions between all employees that take action in the processes.

Analyze phase

  1. Analyze value-added versus non value-added;
  2. Identify and quantify waste reduction opportunities;
  3. Lead a workshop with the stakeholders to guide them in identifying waste sources and to find improvements opportunities.

Improve phase

  1. Elaborate a list of recommendations and an implementation plan;
  2. Create a cost / benefits matrix for the implementation of the different improvements. 

RESULTS 

  • Up to 30 % efficiency gain;
  • More than 1 000 000$ possible additional income;
  • Higher reliability on production delays and faster answer to clients requests;
  • Better control of material handling;
  • Reduction of the non-value added in workstations;
  • Resources optimization;
  • Reduction of the variation between planned hours and real hours;
  • Production planning more accurate.