improving already world-class cycle time

Client: High-Tech Electronics

Challenge:  How does a high-tech electronics company with already very Lean operations by global standards create even better cycle time in its Asian operations?

Methodology:

• A global Aveus team conducted a three-week diagnostic to understand the dynamics of the plant, including process times, queue times, non-bottlenecks and material flow issues.  The team created a new view of existing data that revealed new performance chain opportunities.
• Following the diagnostic, four key opportunities were identified, ranging from busting and managing bottlenecks to creating pull systems. 
• The opportunities were phased, and with 'Quick Wins' implemented immediately the implementation was realized in three months. 
• Aveus team members worked very closely with the client project team to co-develop and implement solutions.
  

Benefits Realized:

• The operation's cycle time was reduced by 20% from an original baseline figure that was already at world-class levels.
• Performance improvements are sustained by smart process methodologies and team commitment.
• Knowledge transfer to the client included: 
• An alternative view and analysis of their existing data
• Knowledge and solutions in analyzing and controlling WIP levels and cycle time variation