Case Study 2
The biggest customer complaint at a commercial manufacturer was the accuracy of the accessory kits included with their product. Too often, there were missing components from the kits, preventing the user from completing installation without replacement.
Using Visual Factory techniques, the assembly area was re-organized for better production flow. Kits were simplified to use common components where possible. Finally, better in-process inspection in the form of automated scales and conveyors were implemented on the assembly line. These improvements eliminated 99%-100% of the complaints from the customer due to incorrect kits with the final product.