Summary
KGC transformed a manufacturing company’s assembly operations by introducing a Warehouse Supermarket System. The solution streamlined part flow, eliminated line stoppages, optimized space, and empowered operators to focus solely on assembly tasks.
The Challenge: Inefficiencies and Disruptions
In the client’s manufacturing unit, operators faced multiple hurdles that hampered efficiency:
- Unpacking, sorting, and inspecting components consumed operator time meant for assembly work.
- Limited line-side space created congestion and clutter.
- Errors, wrong or damaged parts, and shortages were often discovered only at the ‘dropping’ stage, resulting in costly line stoppages and delays.
- With 20+ workstations, the complexity was multiplied.
- Suppliers often rejected claims for damages, citing the long gap between delivery and actual use.
The outcome? Lost productivity, rising costs, and a stressed assembly line environment.
The Solution: KGC’s Warehouse Supermarket System
KGC implemented a Warehouse Supermarket System, a lean logistics solution designed to optimize the flow of components:
Pre-processing in Supermarket Zones
Unpacking and sorting were shifted to supermarket zones near the assembly line.
Tasks were completed a day earlier, reducing last-minute disruptions.
Early Quality Checks
Unpacked parts on racks enabled faster inspection by KGC’s trained team.
Shortages, damages, or discrepancies were detected before reaching the assembly line.
Optimized Material Delivery
Custom-made trolleys carried multiple unique components.
Direct supply to line-side stations ensured a smooth, clutter-free environment.
The Outcome: Efficiency, Reliability, and Lean Operations
The impact of the Warehouse Supermarket solution was immediate and measurable:
- Higher Operator Efficiency – Operators focused entirely on assembly.
- Zero Line Stoppages – Early detection of defects prevented sudden disruptions.
- Optimized Space – Line-side congestion was eliminated.
- Leaner, Reliable Assembly Line – A streamlined process improved productivity and reduced risk.