THE CHALLENGE
A manufacturing factory with a multi-pronged problem of an execution gap because of skilled labor turnover
100+ hours of training
High cost of training workers to meet the technical standards required for the production line
Shift changes
Unplanned absence of skilled workers impact shift planning and productivity
Turnover costs
With a widening skill gap in the industry, trained operators often leave to join competitors
Transformation Strategy
Simplified production plan
Breaking up the task complexity into jobs with a small amount of work in progress inventory
Lean flow process
Introducing a flow line of semi-skilled & un-skilled operators for small repetitive tasks for lean management
On-the-job training
Incorporating training for low-complexity tasks with on-the-job trainers and structured evaluation
Solution Impact
Reduced hiring cost of skilled labor
Increased efficiency with a push & pull system
Increased throughput