6 – 10 Weeks
5 – 7 Months
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Industry: |
North American Automotive Supplier |
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Company Size: |
2,000+
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Project Location: |
United States
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Problem Statement: |
As part of a company wide efficiency improvement initiative, our customer had decided to investigate the die casting process at one of their US plants. The operations management team expected double-digit OEE improvements, if experienced process experts who could share best industry practices, would perform a dedicated Operational Excellence project.
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Meeting: |
Plant tour to get high level understanding of the current die casting process; introduction to production manager, quality manager and die casting supervisors
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Deep Dive: |
Analysis of die casting KPIs to get clear picture on status quo; assessment of every die casting machine, their operators and current performance data (OEE); assessment of maintenance routines, dies and spare parts storage and tool shop; timekeeping of changeovers; root cause analysis for downtime
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Hypothesis: |
The deep dive revealed 3 main operational and organizational weaknesses of the die cast process: preventative maintenance was not performed on a regular schedule, which caused frequent machine failures and downtime. The spare parts stock was insufficiently equipped, so most parts had to be expedited from vendors after the machine part had broken. Only the supervisors were well trained on the die casting machines, the actual operators only had very basic knowledge of how to run the machines. If preventive maintenance routines were established, the spare parts storage sufficiently equipped and the machine operators well trained, a significant reduction of machine downtime would be consequential. |
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Project: |
1 consultants 8 weeks |
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Deliverables: |
Road map with action plan and effective countermeasures developed
Preventive maintenance routines established, controlling tool implemented Spare parts storage well equipped, re-order plan and routines in place All machine operators trained on die casting machines, routines in place |
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Bottom Line Impact: |
OEE improved from 61% to 74%
Expedite costs for spare parts reduced by >90% |
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OEE Improvement
