The IC department is responsible for receiving, inventory management, packaging and shipping. The IC team realigned workflow in the building, eliminating wasted travel time and additional space. They also moved packaging/shipping and receiving, and developed a new layout in the stock room, which led to increased performance 22% better than historically recorded.

Cable / Box / Panel (CBP)

The CBP area is split between the first and second floor of the operation. This team develops custom design work ranging from cable assemblies to large panel builds. The team had multiple start times and collectively recognized the challenges of implementing a continuous one-piece flow process. In order to ensure success, they voluntarily aligned their start times to match up with one another. The layout and scheduling changes led to a 25% overnight improvement in productivity for that area.

Thru Hole

The Thru Hole is the most labor-intense area within AdL Technology operations. Here, components are hand-placed onto boards and soldered into place. The work includes preparing parts for assembly, placement, soldering and finishing work for final assembly. Prior to engaging with Definity Partners, this process flowed through four rooms in a crossing pattern and moved in batches – one person would start a job and complete the next several operations by themselves.

Definity conducted lean simulations to demonstrate the value of a balanced one-piece workflow. During the effort, many workstations were removed, a wall was torn down and the operation was streamlined to reduce waste. These changes resulted in a one-room operation with centrally located prep stations, 50% fewer build stations and smooth flow.

Surface Mount

The Surface Mount function is composed of several highly automated processes. Through daily huddles, the team began to communicate goals and expectations, then resolve the issues that prevent them from hitting these targets. By focusing on utilization and uptime, the team centered their efforts on keeping the machines up and running. Since engagement, their effort has resulted in a 10% performance increase.

Test Department

To ensure the highest quality products, every part moves through the test department for inspection. By revising test and inspection procedures, the team can focus their skill sets accordingly, and highlight areas for development and cross training. 5S activities have helped standardized workstations and create a great visual workplace. The team’s efforts have resulted in a 14% increase in throughput and 50% reduction in accounted-for hours.