Projects

In-progress and unfinished products represents a large amount of inventory in the form of incomplete product.

Problem Statement:

- The factory has 1500 different types of plastic products - 35% of the products (525 products) are always work in progress with an average of 3 days production cycle for each product. - 25% of the work in progress products (131 products) stay in work in progress state for more than 5 days.

Goals:

- Reduce the work in progress products that stay more than 5 days by 50% (from 131 to 66 products) in 6 months. - Reduce the average days of all work in progress products from 3 days to 2 days in 6 months.

Application:

1. Conduct an analysis to determine the reasons behind the delays of the 131 products. This can show issues with machine efficiency, worker skills, material availability, etc.

2. Re-engineer the production line and takt times of delayed products to achieve the target cycle time of 2 days instead of

3. This can be done by balancing the line, eliminating waste, simplifying product designs, etc.

3. Apply lean tools like just-in-time, kaizen, and 5S to remove obstacles and streamline the production flow of all products.

4. Train workers on improving efficiency, reducing errors, and standardized working methods.