Achieved an 87% increase in labor productivity in one station, a 67% increase in another, and a 59% increase overall, within 90 working days.
Key Structures is a young, rapidly growing modular manufacturer in Colorado. As a subsidiary of a major national homebuilder, they have high expectations to ramp up their production quickly to keep up with demand.
Key joined the Lean Offsite™ program in hopes of increasing their productivity, quality, and efficiency, while establishing a more disciplined, Lean culture.
We got right to work with our Lean Offsite™ system, first assessing the process, then measuring the current state, and analyzing it in detail. We then worked with their management team to establish priorities for optimization measures.
In addition, we conducted a comprehensive 5S exercise to organize the workspace for maximum efficiency, and provided Lean training for their line staff and leadership team.
Over the course of the program (less than 90 working days), the factory was transformed. Productivity in one station improved by 87%, throughput on another station went up by 67%, and overall factory throughput increased by 59%.