Project Objectives
A continuous improvement project focused on redesigning the wooden frame assembly process in the carpentry department.
The scope encompassed modifying the construction and design of upholstery wooden frames, transitioning the process to a line flow to boost efficiency and enhancing ergonomics by eliminating unnecessary logistics operations and manual lifting.
The project began with the introduction of a new working concept—unique across the Group—and was implemented gradually in planned phases. The high complexity and dynamic environment, which required making changes during regular production without disrupting output, added to the challenge.
Key Challenges
• Transitioning Innovative Visions into Reality: We designed a new process from scratch and carefully planned its implementation during regular operations, ensuring minimal disruptions to production.
• Redesigning Frame Construction without Compromising Quality: A key part of the project involved modifying the frame construction to make it lighter and more cost-effective, while maintaining the strength and durability of the wooden frame.
• Adjusting ERP Software to the New Production Process: Modifying the ERP system to support the new production workflow was necessary due to the numerous changes in operations.
We played a hands-on role in redesigning the wooden frame assembly process, implementing a line flow system and modifying the frame construction to be lighter and more cost-effective without losing quality. We also actively adjusted the ERP system to support the new workflow, managing each phase to minimize disruptions and improve efficiency while reducing manual handling.
Key Achievements
• Reduced the cost of wooden frame by 35%.
• Improved assembly cycle time by 28%.
• Achieved annual savings of $150,000.
The successfully implemented and proven new assembly model was later rolled out to the other plants within the Group, across five different locations.
