Operational performance improvement initiative focused on on-time delivery and reducing lead time at a curved glass plant supplying production to two windshield system assembly plants.

RESULTS: Three-month assignment identified scheduling issues at the curved glass plant causing excessive changeovers that significantly reduced available capacity. AMG completed a thorough analysis and documentation of current scheduling and ordering processes, change-over requirements for each oven, and demand by product type, volume and frequency. This analysis identified and prioritized opportunities to group parts with similar attributes and created a rotating changeover schedule to allow processing of any group within 48 hours. AMG developed an analytical tool to provide the Scheduling Department with the visibility to maximize production runs by linking daily production to future demand data from the MRP system. Previous 6-month on-time delivery for the curved glass plant averaged 64%. On-time delivery improved to 95% the first week after implementation and continues to improve.