Cellular Layout Adjustment and Standardization
Improve Layout, Material/Process Flow, and Throughput of G.M. Sidestep (Running Board) Assembly Cells.
DeeZee Manufacturing is a medium-sized truck accessory and fabrication company located in central Iowa. Established in 1977, DeeZee is committed to building durable, functional, and stylish products with the consumer in mind. The company is always promoting a cleaner tomorrow by using eco-friendly manufacturing processes and lean practices to reduce emissions and energy use. DeeZee is contracted by most of the large car manufacturers such as Chrysler, Ford, GM, Honda, and Toyota to produce parts for their vehicles. DeeZee has a significant presence in Iowa, with seven large industrial buildings located in central Iowa totaling over one million in combined square feet. These buildings are dedicated to the manufacturing, packaging, warehousing, and shipping of DeeZee products.
Our client, DeeZee, was experiencing several problems with their 3 G.M. running board assembly cells.
1. The current layout around the 3 cells did not have designated floor markings for where materials go.
2. DeeZee’s current automated process was producing a large number of defects, thus reducing the Overall Equipment Efficiency (Refer to Appendix).
3. There was little enforcement of the Standard of Work (rules for employees to do their job-specific).