Operational Excellence Systematic Layout Planning for a Boat Trailer Manufacturer

This study delves into the practical application of the Sawhney Model, a systematic methodology for driving operational excellence, within the context of a manufacturing challenge prevalent in the boat trailer industry. Specifically, this industry segment is engaged in the production of bespoke, high-quality trailers designed for recreational boating purposes. The focus of this problem lies in reducing production costs, increasing productivity, and fortifying reliability within the system responsible for fabricating small trailer components. Employing the Sawhney Model as a guiding framework, an assessment of the existing processes within this system was conducted. Subsequently, it was determined that establishing a novel small parts production line within a newly designated facility space would serve as a strategic recourse for the company. The paper delineates two distinct solutions intended to advance this overarching objective-one oriented towards process performance and the other centered on people. The former entails formulating a production plan and predictive schedule for a fresh production line, enabling the in-house manufacturing of previously outsourced materials. This strategic shift aims to diminish the inventory and associated holding costs significantly. The latter solution focuses on devising a revised layout design for the small parts division. This initiative is projected to optimize the movement of both personnel and materials, consequently trimming cycle time and lead time. This redesigned layout aims not only to streamline processes but also to enhance employee well-being. The culmination of these dual solutions is envisaged to elevate the productivity of the small parts system while concurrently bolstering employee retention.