The manufacturing space efficiency was dramatically enhanced by adjusting rack placement, organizing a bin storage system, improving part labeling, and the use of project construction tables. The manufacturing process itself was improved through the use of inventory reduction, the creation of a process map and a custom packaging scheme.
The three most immediately effective changes were the rack placement, part organization and process map implementations. The combination of these changes resulted in a greatly enhanced production facility that saved floor space and reduced personnel costs dramatically. By changing the rack structure, the company condensed its storage space and allowed easier access to parts. When the parts were reorganized into readily-identifiable bins, the employees were able to increase the ease and efficiency of part procurement. Finally, the use of a process map allowed the managers to construct the production process flow in such a way that the actual time required to build the products was reduced by 50%. The combination of these elements created a process that directly correlated to the stated goals. The company had time and room to grow, adding a new product line without construction of additional facilities.