Process Optimization for the Automotive Industry
In the automotive industry, every second counts. Takt time compliance, supplier quality, and IATF 16949 requirements demand precise process control. LeanShift makes cycle times, OEE, and waste visible, directly on the shop floor.
Challenges
Takt time compliance
Customer takt dictates the pace. Even small deviations cascade through the entire line.
Supplier quality variability
Incoming parts with inconsistent quality disrupt production flow and increase rework.
High changeover frequency
Growing variant diversity requires faster changeovers without quality loss.
IATF 16949 documentation
Regulatory compliance demands traceable process data. Paper-based systems can't keep up.
Relevant KPIs
Typical Process Example
Record current state
Measure cycle times at each station across 15+ cycles with LeanShift's stopwatch.
Identify waste
Muda analysis reveals waiting times, unnecessary movements, and quality losses.
Calculate target state
The target state calculator shows the gap between actual OEE and customer takt.
Run SMED workshop
Separate internal and external setup. Document improvements with before/after measurements.
Verify and standardize
PDCA coaching cycle confirms the improvement. New standard becomes baseline for next iteration.
Typical Results
Relevant Methods
Frequently Asked Questions
How does LeanShift help with IATF 16949?
LeanShift is an analysis tool. It is not a QMS and keeps no audit trail. Every recording carries its recording date and every coaching reflection its date. Exported as a PDF report or an Excel sheet, recordings can supplement your evidence of process improvements.
Can LeanShift handle multi-shift operations?
Yes. Each shift restarts the recording. The fully timed cycles of the previous shift are kept as an archived recording, and the comparison in the analysis overlays the step times of the current and the archived recordings.
What about supplier quality?
Use the stopwatch to time incoming inspections, and it shows the cost per lap in euros. In the Muda analysis, you mark the steps where defects and rework occur and note what happens there.