Production Optimization

MOTIVATION

Our customer, a steel processing company, has long struggled with declining productivity. High staff sickness and turnover was identified as the main reason. Increasingly, they were having to use agency unskilled labor instead of skilled machinists and locksmiths.

analysis of the production process

identified inadequate ergonomic conditions

SOLUTION

We first analyzed the production process to see where there was potential for improvement. We identified inadequate ergonomic conditions in the workplaces as the primary cause of low productivity. We put measures in place – quick wins, and we also set up action plans to help meet production targets in the long term.

CONCLUSION

Thanks to our measures (introduction of 5S standards, visualization, optimization of material flows, elimination of work in progress) we could see already a gradual increase in labor productivity of 10% after 2 months. Furthermore, we proposed the reorganization of workplaces and the introduction of ergonomic aids (exoskeletons, mats) to improve the quality of the working environment. The expected benefit is a reduction in long-term morbidity of up to 30%, which both employees and management are genuinely pleased about.