Planning & Implementing Lean Manufacturing Processes into Plant Expansion to Increase Production Capacity

Assignment

Support modular home manufacturer in plant expansion with a goal to increase production capacity by 250%; Provide highly experience consulting engineers and manager to assist with Value Stream Mapping (VSM) Workshop, implement facility modification project, and establish lean manufacturing concepts.

 

Results

Achieved client's goal to increase production by 250% through Value Stream Mapping, lean manufacturing, and plant expansion.

Challenges/Tasks

  • Production limited by space constraints, access limitations, and inadequate process flow in existing production facility.
  • Aggressive two-year master plan outlined production capacity increase of 250%, requiring additional skilled resources to plan and implement expansion.
  • Resource requirements included 25+ years’ experience launching new plants, products & equipment with focused experiences in lean design systems, project management & facility engineering.
  • Close coordination with client team to establish Value Stream Mapping deliverables, job scopes, and timeline; deliver technical expertise in workshop setting.
  • Maintenance of project tracking wall; reporting of progress and yearend facility rearrangement.
  • Coordinate all lean manufacturing layout modifications for material storage, movement, and operator functional use.
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