Company “A” were seeing extended manufacturing times as production levels became erratic, production would slow to snail’s pace for a period and then return to normal. Overtime was high in an attempt to get production back on track.
Upon investigation it was determined that the manner in which goods were supplied to the production line had to have some level of adjustment prior to them being used. As a new batch arrived production would stop work and adjust a batch of the incoming components and then return to production. They would then consume the batch and then stop production again. Further down the line the next step in production were then idle waiting for product to work on.
How the goods interfaced to the production was rectified at source and the paused production issues ceased. The cost benefit was more than $400, 000 per annum.