Innoven OHS

Jimmy Possum

Background Situation

A medium sized furniture manufacturer was at the stage of moving to another site because they had run out of space and exhausted their power supply at their current site.

Their range of products consisted of high end market furniture made to order from virgin and recycled timber.

They were also making a commitment to implement Lean manufacturing principles into their organisation. GOTAFE was asked to train key personnel in Lean manufacturing within the framework of the Certificate IV in Competitive Manufacturing.

Initial Approach & Observations

GOTAFE has as its brief to improve business performance and to develop personnel so that improvement can be ongoing without the reliance of GOTAFE expertise.

For this organisation a diagnosis was conducted by developing a Value Stream Map (VSM) of the tables which were manufactured from recycled timber.

Opportunities identified from the VSM included:

Batch production increased lead time
Scheduling was constantly changed due to hold ups in production or urgent orders
There was an unacceptable percentage of rework due to quality defects
Production was delayed while waiting for equipment to be vacated

Education Approach

To improve businesses the GOTAFE approach is to develop a learning program around the identified needs of the business. The required knowledge is then provided at the ‘right’ time so that it can be immediately applied to improving the business performance. Clients are required to make change through implementing projects. Change management techniques are incorporated into the learning of the lean principles to facilitate project implementation.

GOTAFE staff partner clients by co-owning the project outcomes through an extensive mentoring program, both on site and by remote access. This reinforces the training and ensures change implementation.

Key Actions

Sort, set, shine, standardise & sustain was conducted in the cutting area
Standardised work was introduced in critical areas
Scheduling was changed from twice weekly to daily
Batch sizes reduced to one
Pull system implemented by using trolleys to control flow and store work in process
Installation of full size kan-ban squares in the finishing area
Foam supply is pre kitted by supplier as complete jobs
Foam delivery made weekly
Kan ban ordering system implemented in upholstery area

Outcomes

Sufficient space was created to enable the creation of a design & development area
Power supply is no longer at maximum usage
Five pieces of equipment were removed with no loss in productivity
Production lead time was reduced by 25%
Work in process timber was reduced by $60,000
Foam inventory was reduced by $30,000
Finishing output per man hour was increased by 33%
Increased flexibility in production
Pressure exerted on Sales for more orders

Contact GOTAFE's Manufacturing Commercial Manager to find out how to improve your business and develop your people. Call 1300 GOTAFE (1300 468 233).

Authorised by: John Bursill
Page updated on September 14, 2010 13:20 by Webmaster SK

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