Industrializing a new line twice as fast
A manufacturer had to launch a new line, fast and right. By working flows from the design phase, service entry was halved and cycle time significantly reduced.
Study a similar needIndustrializing a new line
5 months
from study to production
−40%
cycle time
+3 shifts
activatable at constant floor space
Orders of magnitude observed on the project.
The challenge
The project started with a long installation lead time and a line sized for several shifts, with a high cycle time. The product risked arriving too late on its market.
The real challenge was not to buy equipment but to think through the stations and flows before freezing anything.
Our response
We designed and rolled out the whole line in modular tubular structure, working flows from the very first study.
Workstation balancing planned upfront to smooth out cycle time.
Modular tubular structure: the line installs fast and is correctable without major works.
Dynamic racks and FIFO to remove waits between operations.
Quick service entry, in stages, to produce as early as possible.
Capacity margin built in from day one, activatable later without reinvestment.
« The time saved at design stage we got back many times over once the line was running. We started producing much earlier than planned. »
Other workshops we transformed
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