Mack Truck Chasis & Axle Manufacturing

  • Implemented Kan-Ban inventory controls at Chassis line set for Steering gears and Driveshaft’s
  • Implemented Live broadcast scheduler to build Chassis’s in sequence
  • Increased throughput by 40%, reduced floor space by 70% and decreased cycle time by 50%.
  • Established Supermarkets with train routes for the Chassis line turning inventory every hour
  • Established PDCA to Chassis line side to effectively reduce Quality defects
  • Reduced external defects from 8 to 3 per 100 sequenced unit
  • Established Business Operating System for reporting key indicators by department
  • Reduced Chassis HPU (Hours per Unit) from 31.8 to 25.6 while ramping volume to 84 units/day
  • Improved P/L statement by $200K/month
  • Established Plant Communication System on the manufacturing floor for all employees
  • Plant Communication boards such as Plant Kaizen Events, Product Quality, HSE and BOS.
  • Implemented World Class 6S Programs throughout the plant.