Current design produced poor quality with excessive rework and higher cost.
Vulcan Sales and Engineering reviewed current design to fully understand the issues. Meetings were held with people representing different areas of the Company. All of the current issues were listed along with a “wish list” of marketing related enhancements. Vulcan prepared a presentation that reviewed the current design and offered various design for assembly improvements. A good, better, best scenario was reviewed with the Team and a final design was selected that offered improved quality, several new product features and a cost that met the Customers budget.
A container Kanban system was implemented to provide complete tested assemblies as required using weekly Customer pickups. Customer WIP, rework and excessive finished goods inventories were eliminated. Product enhancements were offered to allow the finished product to be distributed into new markets that had regulations that prohibited the old style design.