Hayssen - Ultima Flow Production (2014)

Client:

Hayssen

Category:

Commercial Sector

Description:

Company: Hayssen Flexible Systems – A Barry-Wehmiller Company ​ Industry: Design and manufacturing of Horizontal and Vertical Baggers and Wrappers, primarily for the food industry ​ Project: Lead Time Reduction/ – Manufacturing & Assembly Operations ​ Size: 1,000 people on a global footprint involving 6 major divisions

Assignment:

A Value Stream Mapping (VSM) exercise highlighted long lead times through the manufacturing and assembly operations as detrimental to customer satisfaction, the perceived value of the Hayssen brand and competitiveness in the market. Traditional ERP based push style production scheduling and sequencing were identified as principal contributors to the long lead times. As is the case with most push style production systems, inventories were high and yet the right part never seemed to be available at the right place at the right time, keeping frustration levels high among scheduling and production personnel. Having facilitated the VSM, MainStream was contracted to facilitate the execution of a Kaizen event to increase the flow of material through production and reduce standard lead times.

Action Solution:

A Value Stream Mapping (VSM) exercise highlighted long lead times through the manufacturing and assembly operations as detrimental to customer satisfaction, the perceived value of the Hayssen brand and competitiveness in the market. Traditional ERP based push style production scheduling and sequencing were identified as principal contributors to the long lead times. As is the case with most push style production systems, inventories were high and yet the right part never seemed to be available at the right place at the right time, keeping frustration levels high among scheduling and production personnel. Having facilitated the VSM, MainStream was contracted to facilitate the execution of a Kaizen event to increase the flow of material through production and reduce standard lead times.

Result:

• Lead Time was reduced from >10 days to a repeatable 5 days

• Inventory requirements were reduced by 30%

• 1500 sq ft of floor space was made available for an incoming product line

• Customer and Employee satisfaction increased dramatically