A clean-slate approach liberated project teams from outmoded constraints. Benchmarking, brainstorming, knowledge sharing and VBSS sparked innovative ideas.

A vendor-managed inventory system now posts Weinstadt’s requirements on the Internet. Suppliers deliver every two to three days versus four to six weeks, reducing inventory. At the warehouse, and later on the shop floor, sensors scan bar-coded parts for increased stock accuracy and instant replenishment.

Robotic devices and a “subway” system of trolleys speed movement of parts to prevent bottlenecks. Color-coding of trolleys and workstations lets operators gauge work in progress.

Employees are cross-trained so they can follow the product from one process step to the next for greater efficiency. Flexible workdays enable operators to fill that day’s orders and leave for home with a greater sense of accomplishment.