Background:
The central location
of Legendary Logistics, Mississauga, enabled opportunity to come knocking
at the door one day. Having already established and implementing a small
in-line-vehicle sequencing operation for exterior colored parts on the
Ford Mustang, Ford Motor Company sought to leverage the knowledge at Ford
at their Oakville Assembly Plant, and a material sequencing centre of
seven commodities.
The advantages are multiple for Third Party Sequencing
Operations at Ford Motor Company:
* Safety: Right Part delivered at Right
Time results in: lower First Time Office Visits, and Lost Time Case Rates
* Quality: Workstation length reduction increases time to inspect part for
defects, coupled with Non Value Added Work Time at each station reductions
shown in
* Increased % of Zero Things Gone Wrong Vehicles produced.
*
Lower warranty cost per unit produced
* Delivery
Reduction of in-plant
MP&L unit load delivery with increased packaging densities results in:
- Improved Build-to-Schedule Numbers.
- Minimized Production losses.
*
Cost:
- Significant labor and handling savings- $750,000 Annual Vehicle
Savings for life of V229 program
- Cost efficiencies achieved in waste
disposal by utilizing returnable packaging.
* Morale:
- Improved operator
morale with ergonomically correct workstation design as seen in Presenteeism Metrics by plant
- Ownership of workstation achieved through
involvement of operator in workstation design revisions.
* Environment:
- Waste Disposal Savings with migration to Returnable Container Savings.
- Raw Material Scrap Reduction- Parts used directly from shipping
containers, instead of traditional method of removing and setting in
workstation closer to operation before installation into vehicle.
Realizing the location, size, and cost advantages Legendary Logistics
provides, Ford sought Legendary Logistics to convert approximately
40,000 sq feet of their 110,000 sq feet facility into a fully operational
material sequencing centre for seven commodities.
Solution:
- Faced
with a four week window to completion, Legendary leveraged existing
synergies of the workforce, along with the experience of our leaders, and
transitioned the facility in 3.5 weeks.
