Page 303 - How To Implement Lean Manufacturing

280 Cha pte r Se v e ntee n

Base Case—Welding Machine Reliable, Sensor Supply Resolved
Dev. Avg. SD for Total
Daily from for the the Weekly Weekend
Prod Goal Week Week Prod’n Run
21 37 1
22 35 –1
23 36 0
24 32 –4
25 40 4 36.00 2.92 180 0
26 38 2
27 35 –1
28 37 1
29 30 –6
30 35 –1 35.00 3.08 175 5
Avg. 35.63 2.89
TABLE 17-3 Production after Welding Machine and Sensor Countermeasures
(Continued)

In this six-week period, additional progress had been made, specifically:

• Zero shipments had been missed.
• Production had improved by an additional four units per day.
• The production variation shrank from 7.6 to 2.9 units.
• Weekend work was reduced to practically zero.

Summary of Results
The summary of results is shown in Table 17-4.
Demand could now be met, overtime practically ceased, there was no need to airship
product, labor cost was reduced, and the product was once again profitable. As a result,
almost everyone was happy.

Prod Std. Dev. of Missed Weekend
Rate Rate Shipments Production
Base Case 28.20 10.66 26% 196
Fix Welding Machine 31.68 7.62 4% 108
Eliminate Stock Outs 35.63 2.89 0% 11

TABLE 17-4 Summary Results