Clay Precision

Clay precision needed to increase capacity in order to continue to grow the business. Management wanted to explore all opportunities to improve throughput by optimizing current manufacturing systems before investing in new equipment or expanding the facility.

Assessment
Ellison Technologies performed an assessment of Clay’s shop floor capabilities, identifying several areas of opportunities to improve throughput without investing in additional equipment capacity. Long setups were eating into machine availability primarily due to lack of pre-planning and excessive foraging for tools during changeovers. High amounts of WIP inventory sat waiting for transport to the next workstation, cluttering the work area, slowing throughput and eating into valuable floor space. Operators programming at the machine also impacted machine productivity.

Solution
Ellison engineers oversaw the implement of a 5s program to improve and maintain organization of the shop floor. Work surfaces were reduced to further eliminate clutter. Carts or casters were used to mobilize WIP containers to support continuous flow of product through the shop and increase available floor space. The cataloging and downloading of programs helped eliminate programming at the machine, increasing machine availability. Kitting of components for upcoming changeovers reduced setup times, supported by the identification and marking of jaws, tools holders, sleeves, and other items used in repeat orders.

End Result
Management estimates that the impact of streamlining the setup process will reduce overall setup times by as much as 50%. Improved machine availability and workflow will have a substantial impact on product throughput. The 5S program increased available floor space by an estimated 10% - 15%.