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Plant output improvement for Air-conditioner Manufacturer

Background

An air conditioner manufacturer wasn’t able to increase its plant output in spite of doubling its labor and moving to three shift production. As a result, they were not able to meet the market demand for their products.

Solution
  • Identification of constraints for increasing output across the plant based on data collection and Gemba audit
  • Establishment of single piece flow
  • Line balancing
  • Automation of final product testing
  • Introduction of Kanban for material supply to production line
Results

7 fold improvement plant output of air conditioners