Successful case study of Kanban implementation in Automotive sector

1. Case Study
Implantation of KANBAN in a company
belonging to the Automotive sector
A highly relevant FeedBackGround experience in operational
processes concerned a study for the complete improvement of
the layout of a large plant. With the aim of achieving the proper
management of the flow of material within the company in order
to increase productivity and space as well as workplaces, the
KANBAN project synthesized below is a specifically successful case
that changed both the physiognomy and efficiency of an entire
company.
Executive Summary Strategy/Approach
 Our client had serious problems of space FeedBackGround’s contribution to this project was as
follows:
 Loss of productivity (low OEE); operatives carrying  Study of the plant cell by cell
out transfer of parts operations (frequential);
stoppages due to lack of parts  Define an order of integration for the cells in
kanban
 Productive cells with multi-product (various
references) involves changes in equipment and its  Pricing and definition of data for each cell
preparation (rearrangement) (production, customer demand, nª of components,
units per packaging...)
 Oversaturation of fork-lift drivers, cell stoppages due
 Creation of new packing guidelines
to lack of internal transport: 4 fork-lift drivers en 4
warehouses, 2 of which supersaturated  Free-up space in the warehouse and in each cell
 Overstocking of component parts  Definition of minimum stock and put an indicator
light into operation
 Excessive fork-lift traffic and narrow aisles
 Definition of new Kanban warehouse layout and, if
necessary, of the cell
Opportunity Results
 It was advisable to study the company to see how it  Project lasting 18 months (one full-time consultant).
runs and determine its weaknesses Ending April 2013. Current state: 50 % of project
 New products in process of industrialization  250 m2 of productive plant space freed up so far;
aisles also freed up
 Increase in productive space to enable participation
in new business opportunities  Improvement in plant safety and elimination of
supersaturation dels toreros.
 Ensure plant safety (excessive fork-lift traffic and
cramped space for movement)  30 % reduction in unplanned stoppages due to lack
of internal transport.
 Prevent overstocking and improve rotational plant
inventory  Elimination de frequential tasks by operatives in 20
out of 63 cells.
 Clear possibilities for short- and long-term
improvement of general plant OEE, especially as  125 increase in new references in production
regards availability: machine stoppage, cell without the need for new resources
rearrangement (elimination of frequentials), etc.

Contact name: Màrius Mollà and Jose Manuel Martinez
Position: Partner and Director of Projects. Consultant
marius.molla@feedbackground.com Customer Experience – August 2012
Telephone: +34 619762870 www.feedbackground.com