BOTTLENECK MANAGEMENT (QUALITY & QUANTITY) REAR PULL BUTTON T6

VW/YMOS

SITUATION

The supplier YMOS failed with his own force and resources to set up the production processes correctly. As a result the Run & Rate failed with 14 x RED points. This leaded to a situation of  daily special transports, and continuous quality concerns despite the used firewall

NATURE OF SERVICE

Bottleneck Management for to secure delivery of correct parts, prepare and lead run & rate (2TP)

DELIVERABLES

  • Work off back lock, reduce special transport and secure supply chain towards VWN
  • Recreation of assembly cell and bottleneck removement with lean process 
  • Implement 5 S until the 4 S (setting up a standard)
  • Implement and secure FIFO in the assembly area
  • Implement Poka-Yokes actions for secureness of process.

Key Achievements & Results

  • Increased output by 40 %
  • Employee reduction by 30 %
  • Back lock reduction
  • Work off action plan for run@rate (2TP)
  • Started at status RED (14 red, 4 critical)
  • Ended at status YELLOW

Locations

Idar-Obersten (Germany)

Sponsor

Mrs. Achim Bohlen, Marc Frie (VW)

Duration

6 weeks

Team

1 Senior Lean Manager

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