Automotive & Industrial Components

Simpler flow, less work in progress, higher output

Logio analyzed shopfloor work and found ergonomics as the primary driver of low productivity. We optimized material flows and visualized standards across workstations.

Outcome

After 5S, flow fixes, and quick wins, labor productivity rose within weeks and long‑term actions were set to sustain gains. Clearer routines and reorganized workspaces reduced delays and variability across shifts.

Labor productivity in 2 months increased by

+0%

Long‑term sickness expected up to

-0%

Initial challenge

Branch managers ordered manually, which was time‑consuming and error‑prone, causing both overstocked Declining productivity driven by high sickness and turnover, with growing reliance on agency labor.

Project goal

Stabilize output by addressing ergonomic root causes, reduce sickness, and meet production targets with sustainable standards.

Solution

Fix the workplace, unlock the throughput

We combined rapid lean housekeeping with targeted ergonomic changes and a clear action plan.

Diagnose

Mapped the production process, observed workstations, and identified ergonomics as the primary constraint.

Quick wins

Introduced 5S, visualization, and elimination of excess work in progress to stabilize day‑to‑day work

Flow redesign

Optimized material flows and reorganized workplaces to reduce unnecessary motion and waiting.

Ergonomics upgrade

Proposed exoskeletons and anti‑fatigue mats to reduce strain and support safer posture. Set action plans and KPIs to track targets and maintain standards over time.

Solutions implemented

Process Mapping & Analysis

KPI Design & Performance Monitoring

Process Optimization

Intralogistics & Material Flow

Impact

Productivity up with healthier workstations

+10 % labor productivity in 2 months

Measured improvement after 5S and flow changes.

Expected reduction in long‑term sickness up to 30 %

Projected from ergonomic upgrades and workspace reorganization.

Lower work in progress and clearer standards

5S and visualization reduced clutter and variability across shifts.

Workstations reorganized for safer, repeatable work

Aids such as exoskeletons and mats target fatigue and strain in repetitive tasks.

Make ergonomics a lever for throughput

If fatigue and poor flow are capping your output, we can help design practical fixes that last. Let’s talk about a focused improvement plan for your factory.

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