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Bull Metal Builds Large Box Cell!

After the success of creating a “Small Box Cell”, the newest Kaizen Team faced the challenge of building a “Large Box Cell” that would help reduce inventory, control defects, and improve operational efficiencies.  By the end of the Kaizen event, (2) 8 ft. brake presses, (5) welders, and a conveyor were all implemented into a “cell”, which addressed all of the objectives the team faced at the start of the project.  The cell will also promote all the Lean initiatives Bull Metal has developed since the start of our Lean Journey.  By joining processes into a cell, takt times can be established to develop “pull” and “one-piece-flow”.  Demonstration has proved that the cell has reduced the number of steps and operators needed to complete jobs, freeing employees up to improve capacity.  Several of the “7-Wastes” of Lean, such as motion, transportation, and waiting have decreased, but most importantly, work in processes (WIP) has minimized.  The Large Box Cell is another starting point for continuous improvement as Bull Metal finds more ways to become more efficient and find smarter ways to manufacture products.

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