Monday, January 28, 2008

7,500 man hours to 3,600 - Saving with Kaizen

I found a nice article at GrandsForksHerald.com about the often amazing benefits of a full lean implementation.

While the majority of the article concerns LM, this passage about Cirrus Design really stood out to me -

"Coincidentally, Cirrus Design, a neighboring plant in the Industrial Park, went through a similar process back in 2001. The company found its workforce was just too inefficient, preventing it from building airplanes as fast as it wanted. In came the Toyota Production System, also known as lean manufacturing.
Like kaizen, it emphasized continuous elimination of waste and inefficiency. Within just three months, Cirrus Design reduced the number of worker-hours needed to build a plane from 7,500 to 3,600. "

Let's ignore the little mix-up concerning kaizen, lean and TPM and look at those figures.
7,500 worker-hours.
3,600 worker-hours.

Labor hours were more than halved through the implementation of Lean Manufacturing.
Alternatively, one could say efficiency more than doubled!

That's mind blowing.
That's kaizen, that's kanban, that's lean.

We've repeatedly seen that the benefits of lean manufacturing can be found in almost any field. How many times do you have to see figures like this or watch companies like LM succeed before you implement lean?

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