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General Electric | KaizenTrek

General Electric

The target demand for GE’s Arc-Fault Circuit Interruptor (AFCI) line was set for 4000 per shift. The day we arrived was not unusual, and produced 1340. The contract was at risk, as were the jobs of 51 workers and the jobs of additional technical support people.

Using Value Stream Mapping to organize our efforts, the team first addressed several quality,
reliability, and handling issues. We then installed small parts buffers at several locations in the
line, and after a bit of verbal instruction re-started the line. With a few days if additional training,
debugging and monitoring, the line reached a 3950 per shift rate. Other planned improvements
were still waiting, so we expect that number to go up.
Lean flow, though way better than the original congestion, has revealed other problems —
always there but obscured by the mass of materials. The team is focusing on them in future
efforts, and further gains will certainly result.

Remarkably, workers commented that the new system is easier for them than before!
Tripled the production in 8 days, and the workers aren’t working as hard!
A line producing 1340 per shift has 5000 in sight.
How much would you think these improvements are worth?
They cost a small fraction of that, and will return these savings from now on!
Similar hidden capacity is held in your business. Let Kaizen Trek help you get it to work for you!

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