Cell Design

Figure 1, Cell Design

We were called in to improve Essilor’s lab operations.  A System Design analysis revealed complex flows, long flow times, high rework rates and low labor productivity.   We decided that the first step to improving the lab was to design and test out a continuous flow cell with Standardized Work, Pace and Process Control.

The current condition material flow and operator motion are shown in Figure 2 below.  There were many material start/stop points, complex flows and operator idle times.  Inventory pooled up in many locations.  Operators only did one type of work and were very inflexible.  In the Target Design (Figure 3 below), material continuously flows one by one through a U-Shaped cell with minimal material handling and operator motion.  Figure 4 shows pictures of the Before and After layouts.

The results of this first test were:

  • Built-In Quality
  • Increased first pass yield
  • Quality right the first time
  • Standardized Work
  • Balance work to target takt time
  • Pace all processes to bottleneck
  • Work to reduce bottleneck cycle
  • Cross-trained and more flexible operators
  • Fast response to problems
  • Understand the issues in real time to help problem solving
  • Better quality, lead time, efficiency and cost
  • Increase customer satisfaction

The success of this cell led to a complete lean transformation at the lab and a nationwide initiative to transform 20 more strategic labs across the country. 

Figure 2, Before Product and Material Flow

Figure 3, After Product and Material Flow

Figure 4, Before and After

Improvement Metrics

Order Flow Time Reduced 79%

Labor Productivity Increased 131%

Material Handling Reduced 81%