RESULTS ACHIEVED TOGETHER ON THE SHOP FLOOR

Success Stories

Measurable results achieved with teams through lean manufacturing, SMED, factory flow and lean logistics projects.

Discover the lean manufacturing approach behind these projects →

Düzenlenen montaj iş istasyonunda çalışan operatör

Kazakhstan – Lighting Factory

Hourly output3 → 20units / hour

WORKSTATION · STANDARDISED WORK

Hourly output
From 3 to 20 units

The workstation and working method were redesigned. Hourly output increased approximately 6.7-fold.

5S · Ergonomics · One-piece flow

Project details

Starting point

The workstation produced 3 units per hour.

Implementation

The workstation and working method were redesigned using 5S, ergonomics, standardised work, one-piece flow, Kanban and Yamazumi.

Result

Hourly output rose to 20 units: approximately a 567% increase from the baseline, or 6.7 times the original output.

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Kırmızı kablo makarası ve kablo üretim hattı

Türkiye – Power Cable Factory

Annual changeover losses90 → 51.3days / year

SMED · CHANGEOVER IMPROVEMENT

38.7 days per year
recovered for production

At the same production volume, annual changeover losses fell from 90 days to 51.3 days, increasing the time available for production.

Setup analysis · Internal/external tasks · Standardised work

Project details

Starting point

Annual losses from changeover activities totalled 90 days.

Implementation

Using SMED, changeover steps were analysed, internal and external tasks were separated and the working method was standardised.

Result

Changeover losses
Days / year43% reduction

51,3

BEFOREAFTER

Changeover times reduced by 26%–59%, depending on setup type.
Annual changeover losses reduced by 43%: 90 → 51.3 days.
38.7 days of capacity recovered annually for the same volume.

Machine image source: TROESTER ↗

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Traktör fabrikasında montaj hattı, parça besleme rafları ve montaj istasyonları

Türkiye – Tractor Factory

Daily output18 → 40+units / day

FACTORY FLOW · LAYOUT

Output with the same team
more than doubled

Daily output increased from 18 units to over 40 with the same team. One third of the factory floor space was freed up.

Flow · SPS · Kanban · Yamazumi

Project details

Starting point

Daily output was 18 units. The project addressed production flow, layout and material supply together.

Implementation

Production flow and layout were redesigned using kitting (SPS), two-bin Kanban and Yamazumi.

Result

Daily output with the same workforce: 18 → 40+ units.
One third of the factory floor space was freed up.
The inventory D2D indicator fell by approximately 40%.
Production with missing materials fell to 1%.

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Dağıtım aracında koli ve ürünlerin yükleme düzeni

Uzbekistan – Distribution Logistics Company

Order picking%72in less time

LEAN LOGISTICS · WAREHOUSING AND DISTRIBUTION

Order-picking time
reduced by 72%

Warehouse operations in Uzbekistan and distribution processes in Tashkent were improved together. Orders could be prepared and delivered faster with fewer vehicles and staff.

Vehicles: 41 → 27 · Distribution team: 50 → 38
Order-picking team: 51 → 34

Project details

Starting point

The company distributes major brands across Uzbekistan. Its Tashkent operation had 41 delivery vehicles and a 50-person distribution team. Warehouse order picking was handled by a team of 51.

Project scope

Warehouse order picking and distribution operations in Tashkent were addressed together.

Result

Order-picking time fell by 72%. Vehicle and team numbers changed as follows:

Before-and-after comparison of warehouse and distribution operations
Indicator	Before	After	Reduction
Delivery vehicles	41	27	%34,1
Distribution team	50 people	38 people	%24
Order-picking team	51 people	34 people	%33,3

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Success Stories

Hourly output
From 3 to 20 units

Starting point

Implementation

Result

38.7 days per year
recovered for production

Starting point

Implementation

Result

Output with the same team
more than doubled

Starting point

Implementation

Result

Order-picking time
reduced by 72%

Starting point

Project scope

Result

What would you like to improve first in your business?

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Success Stories

Hourly outputFrom 3 to 20 units

Starting point

Implementation

Result

38.7 days per yearrecovered for production

Starting point

Implementation

Result

Output with the same teammore than doubled

Starting point

Implementation

Result

Order-picking timereduced by 72%

Starting point

Project scope

Result

What would you like to improve first in your business?

Hourly output
From 3 to 20 units

38.7 days per year
recovered for production

Output with the same team
more than doubled

Order-picking time
reduced by 72%