Quote:
Originally Posted by omasou
It took 4 years to install, configure and test this before it was ready for production!?
Perfect example of why vendors can't just "scale up" for the current COVID demand.
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No of course not. With a global company the size of GKN, there is huge amount of red tape. As stated in my post and in video our facility was already in full production on G05 for BMW as well as GM, Ford, Fiat/Chrysler, and others. BUT our facility was steadfast in Gear Production the same systems as we started over 25 years ago. When is was hired, it was for a major growth? Production was basically 35,000 Axles per
YEAR. Prior to COVID we were producing 35,000 axles per
WEEK! . there was a team formed to vastly improve manufacturing, reduce WIP and so on. That Team was called True North, I developed 3 full and complete concepts which took months to come to which one would meet all goals for all aspects. Then they go out for quotes, then very long negotiations. Final contract was let in November 2018. Final design and build then began. However, we went through a global takeover and management changed several times. The actual line was completely installed beginning in August 2019 and that video was shot November 2019, as parts of the video stated. It is a complete paradigm shift to production, moving from batch manufacturing with large amount of WIP on hand and large amounts of space, to a single piece full pull system. The only WIP (work in progress) are the batches in heat treat, now other batches at all only one pair at a time. Line speed is complete unit every 30 seconds....Then COIVID hit and orders fell off and yet to come back to full. All parts are 100% tracible to when and where they were produced. Even can tell you who touched every part at every operation. Perhaps you may not fully understand automotive production requirement today but I do not know you nor you know me. but I have been doing this for almost 50 years so I have seen huge changes in manufacturing since I started.