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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%.
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