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POP Displays has completed the conversion of its 500,000 square foot facility in Yonkers to cellular manufacturing in order to optimize efficiency, output and quality. In cellular manufacturing, production is paced. Equipment and workstations are arranged in an efficient sequence for continuous movement of inventories and materials from start to finish in a one piece flow. As a result, defects are spotted and corrected immediately by machine operators before it moves to the next stage. Each machine has a QC sample in clear view and a detailed, multi-lingual job sheet that visually shows where each person on the line stands and their role. Technically trained line leaders, identified by orange wristbands, facilitate on-the-spot decision making. In most production facilities, parts are molded, packed and transported to another location to be assembled, or sub-assembled, and transported a second time for final assembly. This creates waste in cartons, transport time, energy and often results in overproduction. With cellular manufacturing, POP Displays eliminated duplicate shop orders, excess packing and wasted energy. The cell is responsible for production from molding through assembly and packing. The effort to convert the facility was immense and occurred while the plant was fully operational with no impact on production or shipping. Internal systems and procedures were converted and many changes benefitted the overall quality of operations. For example, over 200 job instruction sheets were updated in just a few months. Based on its initial studies, POP Displays has already reduced transactions by 30%. Going forward, POP continues to emphasize continuous improvement and explore best in class manufacturing procedures that improve quality and efficiency while reducing waste. Yonkers makes the actual Supplier selections and then the Sun Capital China support team assist with managing the start up of new projects and any other follow up issues that need on site presence at the Suppliers facility. |
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