The kaizen project redesigned the final assembly cell for Applied Technologies to decrease travel distance and reduce floor space usage. The team analyzed customer demand and takt times to design a custom cell layout that accommodated all product assemblies. Individual work stations were customized and the cell was rearranged to reduce the assembly area by 40% and product travel distance by 63%, meeting targets of 400 square feet and 60 feet respectively.

1. Process: Final Assembly Cell Customer: Applied Technologies Area: Box Build
Kaizen Project: ATA Lean Cell Kaizen Tracking #: 13 Date:
Item # Statement of Purpose: Measures/Actions:
1 Decrease travel distance of chassis builds. a) Compiled TAKT times for every ATA product
b) Analyzed all ATA MPI's
2 Reduce square footage of ATA Box area c) Created cell designed based on a) & b)
d) Build custom Cell & re-arrange adjacent areas.
3 Set up Lean Cell capable of producing qty X assemblies per month. e) Create shadow boards, re-org materials, increase Aegis stations
The team analyzed customer requirements for next 6 months.
Each assembly time was broken down into logical pieces.
The work cell was designed to accommodate all assemblies.
Each work station was custom made by the team.
Metric 1 Metric 2 Results Notes
Baseline: 605sq' 123' Metric 1 = Area used
Target: 400sq' 60' Metric 2 = Product distance travelled
Actual: 364sq' 46'
Improv % 40% 63%
Before After
No tape to define cart
Tape damaged and in wrong area
Project Leader: Team Members: T I M W O O D S S
Ben Yorkey TY, Ricky, Dan J, Billy C, Phil A, Lan C, Sivilay, Angie C.
6/26/2014
PROCESS IMPROVEMENT
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FM-028 Kaizen Rev 1