Lean Manufacturing Assembly Line Production Project for Xantrex
Company Profile
Xantrex is one of the most successful and popular brands of onboard AC power technology. Their products are used in a variety of applications in the RV, marine, military, construction, EMS, bus, work service vehicle, and commercial truck markets. Xantrex ensures its products are put through extensive reliability testing and certifies them to comply with applicable regulatory standards that meet or exceed requirements for safety, quality, efficiency, and environment. With over 40 years of experience in design, engineering, and manufacturing, Xantrex power solutions offer a broad mix of advanced technology with unmatched reliability.
Situation
Impact Washington began working with Heart Interface (now one of the Xantrex Companies) in 20021.
As a result of Lean Manufacturing projects conducted by Impact Washington - NIST MEP at Heart Interface in Kent, Louis Belanger of Xantrex was referred to Impact Washington for Lean assistance. Mr. Belanger was in the process of consolidating Heart Interface's production operations into Xantrex's manufacturing plant in Arlington, Washington. He decided to use Lean Manufacturing principles to reduce the production space used by another one of Xantrex's companies, Trace Engineering, as well as reduce the cost of labor for Trace Engineering's products.
Solution
The improvement process started with an operational assessment using process mapping, Xantrex-supplied future state maps and other Lean Manufacturing analytical tools to identify the most effective way to set up the assembly production area for the six Trace Engineering products. Next, select Trace Engineering employees were trained on Lean Manufacturing principles with a focus on flow production. Finally, using Lean principles as the basis, a Kaizen workshop was conducted, and subsequent follow-up visits were made to ensure that the improvements were sustained.
Results
15 percent in improvement in assembly manufacturing productivity
"Impact Washington - NIST MEP conducted Lean Manufacturing assessment, training, a Kaizen workshop and follow-up activities. As a result of the training and Kaizen workshop, Trace Engineering assembly production process increased its productivity, and the goals of the Kaizen workshop were achieved, for the most part, by the assembly production workers." - Louis Belanger, Vice President of T&M Manufacturing Xantrex (2001)