Increasing production to meet customer demand
Deconstruct the manufacturing process
Focus on cycle overruns in high-priority areas
2x returns on original goal

Streamlining assembly boosts output
Problem:
AutoCo large-vehicle production is constrained by engine output. Executives want to increase the rate of engine production by five jobs per hour.

AutoCo is a major automotive manufacturer whose large vehicle group is extremely profitable, but customer demand for these vehicles exceeds existing capacity

Plant management determined that XYZ Assembly was the primary obstacle to achieving the engine production necessary for the target number of vehicles

As part of a full potential manufacturing improvement program, the Bain team was charged with 

  • improving productivity at the bottleneck machine on the main assembly line
  • improving the yield of the subassembly department feeding the bottleneck machine
  • finding five more engines per hour (JPH) on the XYZ Assembly and on the mainline station it feeds