We work side by side on the shop floor with furniture and wood product manufacturers.
Growing model and color variety, order-based production, rising raw material and energy costs and sustainability expectations are pushing furniture manufacturers to create more value from every board and every machine.
As Gemba Partner, we address the production flow end to end, from panel cutting to edge banding, from painting and upholstery to assembly and packaging.
With cutting planning we reduce scrap rates, make machine OEE losses visible, shorten setup times and speed up the flow from order to shipment. With daily shop floor management and standard work systems we make the gains lasting.
The goal is to build an operation that manages growing variety with less inventory, shorter lead times and lower cost.
With a quick changeover study, setup times on cutting and processing machines were halved; waiting losses during model changes were reduced and output increased.
Material flow and operating standards from cutting to assembly were reorganized; process losses were analyzed to reduce scrap and inventory levels were balanced.
Downtime, speed and capacity losses in the paint shop process were analyzed. By eliminating bottlenecks and improving working standards, output from existing equipment was doubled.
The production flow was redesigned with line balancing, bottleneck analysis and standard work activities. With the same resources, daily output was increased from 500 to 860 units.
Machine, stock and material movements were re-analyzed. With a flow-oriented new layout, the production area was compacted while unnecessary transport and distances between processes were reduced.
Station loads and operator movements were analyzed. The production rhythm of the line was balanced by redesigning bottleneck operations and applying standard work.
Support processes, task allocations and shop floor organization were analyzed and duplicate work was eliminated. The organization moved to a leaner structure while the operational service level was maintained.
From Operational Excellence and Lean Transformation to digital shop floor management, from factory layout to capacity development, we address your production system end to end.
We work side by side on the shop floor with furniture and wood product manufacturers.
Growing model and color variety, order-based production, rising raw material and energy costs and sustainability expectations are pushing furniture manufacturers to create more value from every board and every machine.
As Gemba Partner, we address the production flow end to end, from panel cutting to edge banding, from painting and upholstery to assembly and packaging.
With cutting planning we reduce scrap rates, make machine OEE losses visible, shorten setup times and speed up the flow from order to shipment. With daily shop floor management and standard work systems we make the gains lasting.
The goal is to build an operation that manages growing variety with less inventory, shorter lead times and lower cost.
With a quick changeover study, setup times on cutting and processing machines were halved; waiting losses during model changes were reduced and output increased.
Material flow and operating standards from cutting to assembly were reorganized; process losses were analyzed to reduce scrap and inventory levels were balanced.
Downtime, speed and capacity losses in the paint shop process were analyzed. By eliminating bottlenecks and improving working standards, output from existing equipment was doubled.
The production flow was redesigned with line balancing, bottleneck analysis and standard work activities. With the same resources, daily output was increased from 500 to 860 units.
Machine, stock and material movements were re-analyzed. With a flow-oriented new layout, the production area was compacted while unnecessary transport and distances between processes were reduced.
Station loads and operator movements were analyzed. The production rhythm of the line was balanced by redesigning bottleneck operations and applying standard work.
Support processes, task allocations and shop floor organization were analyzed and duplicate work was eliminated. The organization moved to a leaner structure while the operational service level was maintained.
From Operational Excellence and Lean Transformation to digital shop floor management, from factory layout to capacity development, we address your production system end to end.
