Transforming Efficiency through Spaghetti Mapping/Modelling
In the competitive market of home exterior manufacturing, staying ahead requires not only innovation in products but also in production processes. Titan Exteriors, a leader based in Medicine Hat Alberta, found themselves facing an efficiency bottleneck with the arrival of two new critical pieces of equipment. Constrained by space and time, they embarked on a transformative journey to streamline their operations through Lean methodologies, with the expert assistance of MEE and their specialist Bruce Ennis.
Challenge
Titan Exteriors was on the cusp of a significant upgrade with the purchase of a down pipe machine and an elbow machine poised to enhance productivity. Nevertheless, the installation of this new equipment in their 6,000 square foot facility presented a major challenge due to an already congested work area. The mission was clear but daunting: reorganize a bustling manufacturing floor without compromising the impending increase in production demand.
The Lean Approach
Rejecting the slow burn of traditional approaches, Titan opted for immediate action. Bruce Ennis from MEE was brought onboard, armed with spaghetti mapping—a technique that unveils inefficiency by visually tracing the workflow within a space. By identifying and eliminating wasteful transportation and motion, the intention was to sculpt a facility optimized for seamless operation.
Collaborative Redesign: With the clock ticking, Bruce, along with Titan’s owners Eva and Henry Bartsch, rolled up their sleeves. Over the next 48 hours, they scrutinized every inch of the facility—walls were contemplated for demolition, equipment debated for relocation, and even a neglected lunchroom was considered for repurposing. Their collaborative approach was inclusive, gathering insights from all stakeholders, ensuring a holistic evaluation of the floor’s operation.
Outcome
The outcome of this intense two-day workshop was a radical reimagining of Titan’s production floor. The new design diverged significantly from the original layout; it necessitated substantial changes in the facility’s infrastructure to enact a “first pass” design. Recognizing the iterative nature of process optimization, they prepared a comprehensive task list to guide the implementation.
QUICK TAKE
Challenge: Reorganize a bustling 6,000 sq.ft. manufacturing facility without compromising the impending increase in production demand and make room for a variety of new equipment.
The Lean Approach: Rejecting the slow burn of traditional approaches, Titan opted for immediate action. The MEE was brought onboard, armed with spaghetti mapping. By identifying and eliminating wasteful transportation and motion, the facility could be optimized for seamless operation.
Collaborative Redesign: Over 48 hours, every inch of the facility was scrutinized—walls were contemplated for demolition, equipment debated for relocation, and even a neglected lunchroom was considered for repurposing.
Outcome: The outcome of this intense two-day engagement was a radical reimagining of Titan’s production floor. The new design diverged significantly from the original layout; it necessitated substantial changes in the facility’s infrastructure to enact a “first pass” design.
Key Recommendations
Despite the accelerated timeline, the initial redesign was just the beginning. To build on this foundation, the following steps were recommended:
- Develop a Kanban system for enhanced inventory management.
- Conduct time studies once the new equipment is operational to refine the efficiency further.
- Use the time studies’ results to create an updated spaghetti map leading to a new optimized floor layout.
- Implement staff training sessions focused on the principles of Lean to foster a knowledgeable workforce.
- Empower management with specialized Lean training to lead the company’s continuous improvement initiatives.
- Optimize the process of receiving and storing master coils through a Kaizen event.
- Launch a 5S program beginning with a thorough “red tag” sorting event to streamline the workspace further.
Through swift decisive action, expert collaboration, and a commitment to continuous improvement, Titan Exteriors has laid the groundwork for substantial productivity advances in its manufacturing operations. By embracing Lean principles and acknowledging the necessity of ongoing optimization, they are poised not only to meet the challenges presented by their new machinery but also to scale new heights in operational excellence. This case study serves as a testament to the agility and forward-thinking of both Titan Exteriors and MEE in the pursuit of Lean efficiency.
Final Thoughts
This case study highlights the potential within any organization to revolutionize its processes through Lean principles, where the drive for improvement turns challenges into triumphs of efficiency and productivity.
