📋 Case Study
Automotive Tier-1 Assembly Line Labor Optimization
Chronic overtime, 22% idle time, and inconsistent SMV adherence across shifts
🏗️ Project Overview
High-volume door module assembly line in Ohio
🎯 Challenge
Chronic overtime, 22% idle time, and inconsistent SMV adherence across shifts
🔧 Design Approach
Redesigned cell layout with cross-trained operators; implemented real-time digital labor tracking and daily huddle-based micro-improvements
📐 Design Diagram
AI-generated project design illustration
📐 Key Calculations
Labor Utilization Rate
(Actual Work Time / Available Time) × 100
Result: 78% → 92%
Identified hidden downtime sources
Balance Loss
1 − (Cycle Time / Sum of Station Times)
Result: 18% → 6%
Enabled reduction from 12 to 9 stations
📊 Results
17% reduction in labor hours/unit, $2.3M annual savings, 35% decrease in shift-to-shift variance💡 Lessons Learned
- •Real-time visibility drives behavioral change
- •SMV must be co-developed with operators
- •Daily feedback loops outperform quarterly reviews
✅ Key Takeaways
- 1Real-time visibility drives behavioral change
- 2SMV must be co-developed with operators
- 3Daily feedback loops outperform quarterly reviews
📐 Prerequisites
Understand these before this topic
🔗 Engineering Applications
See how this applies across industries