Stabilizing New Production Operations with Guided Assembly and Visual Management

Summary

When launching a new production site with over 300 operators, a manufacturer adopted Smart Workstations to guide assembly, track production performance, and manage quality in real time, enabling rapid operational stabilisation and cost savings.

Business Challenges

• Rapid ramp-up at a new production site

• Large workforce with varying skill levels

• Risk of high scrap and rework rates

• Limited real-time assembly visibility

Solutions

• Deployed Smart Workstations with guided assembly instructions

• Enabled visual management and real-time production tracking

• Implemented scrap and rework monitoring with alerts

• Integrated Andon notifications for issue escalation

Results

• Achieved 0.2% scrap rate

• Outperformed other sites with 10%+ scrap rates

• Delivered approximately USD 1.2 million annual savings