Report

Napa Rayloc

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C a rpédia Intern a t i o n a l is a management firm uniquely focused on helping leading companies implement sustainable improvements in re v e n u e g rowth, pro d u c t i v i t y, and asset utilization. For more information please visit us at www.carpedia.com / All Rights Reserved 2003 ©C ARPÉDIA INTERNAT I O N A L LT D N a pa Ray lo c is one of the world 9s largest re m a n u- f a c t u rers of post market automotive part s . T H EC H A L L E N G E The exe c u t i ve management group re q u e s t e d Carpédia to aid them in their drive to improve pro- ductivity in a number of their facilities.

This pro j e c t o c c u r red in Payson, Ut a h THE RESULTS The project resulted in a ROI greater than anticipat- ed, focusing on production. Below are the speciBc actions that made the results possible: Improved manufacturing processes "Line balancing the calipers area resulting in a 41% improvement in ... more. less.

productivity (dedicated parts run- ner to keep operators at their stations, eliminated frequency of changeovers by lengthening runs) "Wo rk Cow layout change in the Brake Shoe area that resulted in a 44% improvement in pro d u c t i v i t y "Redesigned warehouse layout to improve material Cow that resulted in a 10% improvement in pro d u c t i v i t y "Reduced unnecessary activities in the Disc Br a k e d e p a rtment resulting in a 12% improvement in pro- ductivity (Installed Cag system to notify part runners of s h o rtages, station elimination and job combination) Napa Rayloc Payson Utah Facility Improved management systems "Improved existing systems to better link Bnancial requirements with operational requirements "Improved scheduling process to ensure compliance with budgets and forecasting tools "Developed Results boards throughout the plant to inform employees of their progress on an hourly basis and enable supervisors to resolve negative variances to the schedule "Developed resource plan to match requirements to forecast Improved behaviors "Mo re timely reaction to schedule variances and re s o- lution of operating problems to meet Bnancial targets "13 fold increase in active management IMPLEMENTED RESULTS T H ROUGH IMPROV E M E N TS IN PRODUCT PROCESS SYSTEMS AND BEHAV I O RS Seize the OPPORTUNITY e-mail : carpedia@carpedia.com www.carpedia.com M r. Art Catlin, General Manag e r: cI would like to thank (Carpédia) for convincing me to enlist the help of (your company) to improve the efficiency of Rayloc Payson.<br><br> It was a hard pill to swallow being told we we re operating at 50% efficiency as we we re having our best year eve r. After picking up my ego off the floor and seeing your process implemented, I have become a b e l i e ve r. I have appreciated working with your professional staff and would recommend yo u r s e rvice to anyo n e .<br><br> d THE T E S T I M O N I A L

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