A global home furniture manufacturer, distributor and retailer with more than 700 retail stores worldwide.
The Challenge Statement
In the furniture manufacturing industry, it is imperative that furniture is assembled with zero defects prior to delivery in a customer’s home. The furniture assembly process was inefficient, redundant and costly. In addition, unnecessary and wasteful product movement was causing increases in manufacturing and handling defects.
- Perform a Kaizen event that encompasses Lean principles and techniques to increase efficiencies, reduce costs and eliminate waste.
- Build a model to illustrate an ideal assembly process of product to enable higher efficiencies.
- Exceed customer satisfaction by delivering zero-defected products to customers’ homes across all corporate locations in the United States.
Develop an assembly process that engages all associates at every level that incorporates all improvement opportunities. Develop manufacturing cells with dedicated tools, workspaces and visual cues that streamlines the assembly process and provide maximum efficiency in processing time.
What Did the Team Achieve?
A functional assembly process that supports prioritization of work that is systematically driven by the in-house ERP system. Incorporated Lean principles such as Heijunka (load leveling), Spaghetti Diagrams, Visual Cues and Process Flow Mapping to assist in the development of a Systematic Business Solution. The process is scalable and can be easily adopted in other markets.
What Results Did the Solutions Yield?
- 72% Reduction In Product Movement
- 18% Increase in Manufacturing Productivity
- 99.8% Customer Satisfaction Rating
- 58% Decrease in Truck Loading Times