The document describes a Lean Manufacturing event conducted to improve the assembly line of a commercial vehicle equipment manufacturer. The assembly line was producing units 3,000 behind demand. A 5S event was conducted and one-piece flow was needed as an example. Experts helped conduct a breakthrough event. As a result, work-in-process was reduced from 12 to 3 units, direct labor time per unit dropped from 8.75 to 4.9 minutes, travel distance decreased, time between units dropped, the number of operators was cut from 7 to 3, the line length shortened, and annual savings reached $300,000. The line now flowed in one-piece flow with no waste-in-process,

1. Conducted at Masterack®
• Product line 3,000 units behind demand
(target 1,000/week)
• Top Plant Management trained in Principles
of Lean Manufacturing
• 5S performed near area
• Example needed for One Piece Flow
• Wanted outside help to perform
breakthrough event
Commercial Vehicle Equipment
A Division of Leggett & Platt Inc.

2. Before After
Work In Process 12 units 3 units
Direct Labor per unit 8.75 min. 4.9 min.
Direct Labor travel 90 feet 33 feet
Time between deliverable units 5.62 min. 2.32 min.
Number of Operators 7 3
Length of assemble line 32 feet 10 feet
Square feet 840 440
Incoming defect tracking None Initiated
Standard Operating Procedures None Initiated
Direct Annual Savings $300,000
One Piece Flow

3. Assembly
Line Here

4. Assembly Line
• 40 ft. of Conveyor, plus Pallet
• Seven People per Shift | 2 Shifts
Start on Left | Finish on Right

5. Output End
• 12 Units per Pallet
• Units Lifted onto Conveyor for Strapping
• Units Completed on Floor

6. Operator must
stand on
something to
reach part.

7. Unit,
Spacers
and
Shipping
Container

8. Team Studies
Observations
• Time Measurement Data Analysis

9. New Ideas
• Lower Conveyor
• Remove ‘Wings’ From Conveyor

10. Shipping
Bottom
Doubles as
Assembly
Cart
No Floor Work
or Tipping
Just Add Top
and Strap

11. Team Members Discussing Ideas

12. More Ideas with Video Taping for Further Study

13. Tools Moved from
Conveyor to Holder
Inexpensive Experiment
Using Cardboard & Tape

15. • 10 Ft. of Conveyor (40 Ft. Previously)
• 3 Operators (7 Operators Previously)

16. • No WIP Between Operators
• Smooth Operations | Less Noise
• Work at Comfortable Height• Parts Near Workers & Workstations
• No Processes on Floor
• Work Content Time Reduced