By implementing DFT, Torotel has experienced an increase in production capacity and reduced floor time in our manufacturing department. For our customers, that equates to more expedient, cost-effective product delivery. To see how DFT has helped Torotel achieve better, more efficient product delivery, please read below.

SUCCESS STORIES

Increased Production Capacity

Problem: Area needed for the manufacturing process exceeds our available floor space.

Solution:
• We use Value Stream Mapping, enabling us to list and analyze each
   process. Those that do not add value are eliminated.
• Takt Time, like a metronome, keeps our processes at a stable rhythm so no
   station is moving too quickly or too slowly.
• A Spaghetti Diagram allows us to draw and measure each process to
  analyze material flow and identify opportunities for improvement.

Results:
• 19% reduction of material travel
• 5000 square feet of floor space created available for production
• Work cell shipped 100% of all past dues within three months
• 188% additional capacity for conformal coat department
• Reduced cost of transportation for conformal coat by 8%

Reduced Floor Time

Problem: The average job is on the floor for 69 days.

Solution: Use value stream mapping, Kanban, and sequencing to identify improvements. We consistently track all parts during manufacturing, which enables us to improve our processes on a regular basis.

Results:
• The average flow time decreased from 67 days to 28 days
• WIP decreased 60%
• The lead time quoted has been reduced by 50%.