Within the manufacturing operation the complete demand chain, supply chain and manufacturing process was analysed. To understand the manufacturing process, discussions were held with all the functional stake holders and analysis of the production flow to and on the production line was carried out.

The review of the manufacturing operation revealed the line layout was unnecessarily complex as there were a number of additional stages and additional operators that were required.

Reviewing the operator’s tasks and the complexity of the line layout it was found, complexity could be removed and the number of operators required to complete the customer order for the month could be reduced.

The modifications to the production line were carried out with limited investment and there was a dramatic effect on productivity, efficiency and a reduction in total cost per unit. The review of the line layout also revealed, having components located close to the point of use, could have a dramatic effect on model change overs.

Having the correct processes and procedures in place is very important and a review was instigated of the line clean down procedure and the procedure of returning stock to the warehouse. This review eliminated the possibility of defective stock being despatched to the customer.