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Health checkTOC Case Study: Ford Motor Company
Electronic Division Experience
LEAD TIME(from release of material until shipping)
AVERAGE ON ALL SITES FOR ALL PRODUCTS
- Before improvement project: 10.6 days
- After two years of implementing JIT: 8.5 days
- After one year of implementing TOC: 2.2 days
- Currently: Less than two shifts
- Customer satisfaction improved >75%
- Able to move to real time SPC on the floor
- Responsiveness and learning 300% faster
- 20% more floor space allowing introduction of new products
- Material handling and tracking reduced 50%
- Facilities investment reduced 25%
- Suggestions process went from 150 days to 10 days
- Scheduling process went from 16 days to 5 days to 1 day
