Lean transformation for high mix low volume production: A case study

Abstract

In this paper, we propose a systematic lean transformation to improve the quality, reduce the cost and lead time for the high-mix, low-volume manufacturing that has been implemented in Schlumberger Houston Product Center, which has a typical high-mix, low-volume production environment. The success of the manufacturing transformation relies on three strategies. First, the zero-defect-out strategy aimed at achieving superior quality in manufacturing, which is comprised of varies of corrective, preventive and sustainable actions. Secondly, the cellular manufacturing system design was implemented to resolve the issues of excessive work-in-process, transportation moving bottlenecks, prioritization conflicts, etc. Finally, the total employee involvement organization was established to improve employee's performance on quality, productivity, responsibility, accountability, creativity and dealing with challenge and change. The lean transformation has resulted in reduced scrap rate and lead time, and significant cost savings.