Challenge:
An automotive parts manufacturer struggled with low productivity due to machine downtime and inefficient workflows.
Solution:
Lean TPM (Total Productive Maintenance) was introduced to reduce downtime. Hoshin Kanri established machine uptime as a strategic focus, while the Balanced Scorecard monitored operational KPIs such as OEE (Overall Equipment Effectiveness), production rates, and quality.
Outcome:
- Machine uptime increased by 30%.
- Productivity improved by 25%, generating $4 million in additional revenue.
- Defect rates reduced by 15%.